WATER HEATER
INSTALLATION MANUAL
ELECTRIC WATER HEATER
INSTALLATION AND OPERATING INSTRUCTIONS
Read these instructions thoroughly before starting
TABLE OF CONTENTS
I)
Water Pipe Connections ........................................1
II) Power Supply \ Wiring ..........................................1
III) Filling & Draining Tank ..........................................2
IV) Installation Checklist ..............................................2
V) Temperature Adjustment ........................................2
VI) Service And Maintenance ..............................2 to 3
VII) Trouble-Shooting....................................................3
VIII) Pressure Buildup (Thermal Expansion) ................4
IX) Warranty ................................................................5
PLEASE RETAIN THESE INSTRUCTIONS IN A
SAFE LOCATION FOR FUTURE REFERENCE
FOR YOUR SAFETY
• Do not store or use gasoline or other
flammable vapours and liquids in the
vicinity of this or any other
appliance.
• Installation and service must be
performed by a qualified installer,
service agency or the electric utility.
WARNING:Improper installation,
adjustment, alteration, service, or
maintenance can cause injury or
property damage. Refer to this
manual. For assistance or additional
information, consult a qualified
installer, service agency, or the
electric utility.
INSTALLATION RECORD
This water heater is protected by a multi-year warranty against leaks
plus a one (1) year warranty on parts.
Record key data here for future reference and prompt service:
WARNING: If the information in
these instructions is not followed
exactly, a fire or explosion may
result causing property damage,
personal injury or death.
Installed By / Purchased From:
Installation Date:
Model Number
Location of Electrical Switch
or Circuit Protector:
Serial Number
IF YOU HAVE ANY INSTALLATION, PERFORMANCE
OR OPERATIONAL QUESTIONS PLEASE CALL THE
FOLLOWING NUMBER, PRIOR TO REMOVING THE
WATER HEATER
Watts-Total
U.S. Gal.
Watts
Volts
Watts
P.S.I.
(if this is a rental water heater please contact the rental
company)
1-888-GSW-TECH
1-888-479-8324
PART NO. 61515 REV. C (03-01)
Download from Www.Somanuals.com. All Manuals Search And Download.
FILLING TANK
1. Close the drain valve, and then open a hot water faucet.
2. Open the cold water supply valve.
3. When water runs out of the hot faucet, the tank is full.
4. Check the system for leaks.
NOTE: When filling, avoid water spillage. Do not allow the insulation of
the heater to get wet as water can cause electrical malfunction.
CAUTION
FOR YOUR SAFETY, BE AWARE THIS WATER HEATER
IS CAPABLE OF PRODUCING HOT WATER AT
A
TEMPERATURE SUFFICIENT ENOUGH TO CAUSE
SCALDING INJURY. READ INSTRUCTIONS CAREFULLY
BEFORE OPERATING THIS UNIT. INCREASING THE
THERMOSTAT SETTING ABOVE THE PRE-SET
TEMPERATURE MAY CAUSE SEVERE BURNS AND
CONSUME EXCESSIVE ENERGY. HOTTER WATER
INCREASES THE RISK OF SCALD INJURY.
150°F (66°C) – 2 SECONDS
DRAINING TANK (completely)
If the power is to be turned off during the cold season and the tank is exposed
to freezing temperatures, the water heater must be drained. Water will expand
when it freezes and can damage the heater.
140°F (60°C) – 6 SECONDS
130°F (54°C) – 30 SECONDS
Completely drain as follows:
1. Make sure the electrical supply to the water heater is “OFF”.
2. Turn off cold water supply.
3. Connect a garden hose to the end of the drain valve and direct this to a
point lower than the heater.
4. Open a hot water faucet.
5. Open the drain valve on the heater – drain, keeping the drain valve open
during the shutdown period.
6. To refill the heater, see ‘Filling Tank’ section.
TEMPERATURE ADJUSTMENT
In order to reduce the risk of scald injury, thermostats are factory set at
120°F (49°C). The thermostats operate automatically. They can be adjusted
to provide warmer or cooler water temperature. The setting of 120°F (49°C)
has been proven to be most satisfactory from the standpoint of operational
costs and safety. We recommend you keep the thermostats adjusted to
120°F (49°C). If adjustments are made set both thermostats to the SAME
setting (if applicable).
INSTALLATION CHECK LIST
1. Are the fuse and wire sizes correct?
Check Here
TEMPERATURE LIMIT CONTROL
2. Is the certified relief valve installed?
For safety, a non-adjustable high limit temperature switch will shut off the
power when excessive water temperatures are reached. This switch must be
re-set manually. See ‘Trouble-Shooting’ section.
3. Are you sure that in case of water leakage, the building,
furniture, carpeting or other property will not be damaged?
4. Has the relief valve been piped to a suitable drain point?
5. Is the relief valve discharge unobstructed?
6. Is the heater completely filled with water?
7. Is the cold supply valve open?
WARNING
BEFORE ATTEMPTING ANY ELECTRICAL
REPAIRS OR REPLACEMENTS, TURN OFF POWER TO THE
WATER HEATER. CHECK WITH A VOLTAGE TESTER AT
TERMINAL 1 AND 3 OF THE LIMIT CONTROL THAT POWER IS
INDEED OFF. FAILURE TO DO SO MAY RESULT IN ELECTRIC
SHOCK AND/OR ELECTROCUTION OF THE PERSON DOING
THE WORK.
If the answer to the above are yes, turn on the power and enjoy all the hot
water you need, all the time.
If water temperature adjustment is required:
RELIEF VALVE REQUIREMENTS
1. Turn the electrical supply to the water heater “OFF”.
CAUTION To reduce the risk of excessive pressures and temperatures in this
water heater, install temperature and pressure protective equipment required
by local codes. It should be no less than a combination temperature and
pressure relief valve certified by a nationally recognized testing laboratory
that maintains periodic inspection of production of listed equipment or
materials, as meeting the Requirements for Relief Valves and Automatic Gas
Shut-off Devices for Hot Water Supply Systems, ANSI Z21.22-latest edition.
This valve must be marked with a maximum set pressure not to exceed the
marked MAXIMUM working pressure of the water heater (150 PSI). Install
the valve into an opening provided and marked for this purpose in the water
heater, and orient it or provide tubing so that any discharge from the valve
will exit only within 6 inches above, or at any distance below the structural
floor and cannot contact any live electrical part. The discharge opening must
not be blocked or reduced in size under any circumstances.
2. Remove the access door(s), and turn back insulation.
3. Adjust the thermostat(s) to the water temperature desired (if a two-
thermostat system exists, set both thermostats at the same temperature).
4. Repack the insulation and replace access door(s).
5. Turn the electrical supply to the water heater “ON”.
ELEMENT REPLACEMENT
1. See ‘Draining Tank’ section to remove water from the heater.
2. Turn the electrical supply to the water heater “OFF”.
3. Remove the access door(s), and turn back insulation.
4. Disconnect wires from heating element terminals.
5. Unscrew the element using a 1½” socket wrench or tool number S1008,
available from your water heater distributor.
6. Replace element with new one, taking care that sealing gasket is in the
groove of element flange.
7. Re-connect wiring, and replace Di-Electric shields.
8. Repack insulation over thermostat(s), and replace access door(s).
9. Fill tank with water BEFORE turning ELECTRICITY on. See ‘Filling
Tank’ section.
The end of the relief pipe opening should terminate near a floor drain or other
suitable location not subject to blocking or freezing. DO NOT thread, plug or
cap the relief pipe opening.
THERMOSTAT REPLACEMENT
1. Turn the electrical supply to the water heater “OFF”.
2. Remove the access door(s), and turn back insulation.
3. Disconnect wires from thermostat(s).
4. Lift prongs off bracket and slide thermostat up and out.
5. Replace in reverse order, taking care that thermostat(s) is flush against
the tank.
FAILURE TO INSTALL A LISTED ¾” TEMPERATURE -
PRESSURE RELIEF VALVE WILL RELEASE THE
MANUFACTURER FROM ANY CLAIM WHICH MIGHT
RESULT
FROM
EXESSIVE
TEMPERATURES
AND
PRESSURES.
6. Repack insulation over thermostat(s), and replace access door(s).
7. Turn the electrical supply to the water heater “ON”.
TEMPERATURE & PRESSURE RELIEF VALVE
Inspect the relief valve annually to ensure proper operation. This involves
opening the valve to check that water is able to flow freely, and that there are
no blockages. Warning: THE WATER WILL BE HOT and its flow can be
forceful. Provide a bucket or drainage for the expelled water. Lift the lever
and let it snap shut. The water should stop immediately.
If the valve does not function properly, it MUST be replaced. In systems
where the relief valve discharges periodically, this may be due to thermal
expansion causing pressure build up. See ‘Pressure Build-Up (Thermal
Expansion’ section.
CATHODIC PROTECTION: ANODE MAINTENANCE
Your water heater has been supplied with an anode rod that protects the tank
from corrosion. As the rod works, it slowly dissolves over time and must be
replaced. If the anode is less than 3/8” diameter, or any exposed bare core,
replace. Depending on water conditions, an anode can last from one to ten
years. Many localities treat their water, which can have significant effect on
the life of your heater. Water conditioning such as over softening can
accelerate the rate at which the anode rod is consumed. Rapid depletion can
leave a heater unprotected causing a premature failure. As with any water
heater, it is good practice to check the anode annually to see if it needs
replacing.
2
Download from Www.Somanuals.com. All Manuals Search And Download.
ANODE INSPECTION / CHANGE
1. Turn the electrical supply to the water heater “OFF”.
2. Close the cold inlet supply valve.
3. Open a hot water tap supplied by the heater. (CAUTION: Water will be
hot).
HOT WATER ODOUR
On occasion, and depending on your location, hot water may develop a
strong odour. This can be especially problematic in regions where the water
contains some sulphur, which results in hot water having a “rotten egg”
smell. If this occurs, drain the system completely, flush thoroughly and
refill. If the problem persists, the anode rod may need to be changed from
magnesium to one made of aluminum. In certain cases chlorinating and
flushing of the water heater may be required. Contact your dealer or water
supplier.
4. See ‘Draining Tank’ section to remove enough water to empty the piping
system.
5. Using a 1 1/16" socket, remove anode and inspect or replace as required.
6. To refill the heater, see ‘Filling Tank’ section.
WARNING Operating a water heater without an actively working
anode rod will void the warranty.
DISCOLORED WATER
• Water rich in iron or other minerals can produce red or brown staining.
Heating water generally worsens this situation.
TANK CLEAN-OUT
1. A clean-out opening is provided on certain models for periodic cleaning
of the tank. Power supply must be shut off and the heater drained before
opening the clean-out.
2. To clean heater through the clean-out opening, proceed as follows:
a) Remove outer door from side of the casing.
b) Peel back the insulation covering the clean-out flange.
c) Remove the six (6) hex head screws securing the tank clean-out plate
and remove the plate.
d) Remove lime, scale or sediment using care not to damage the glass lining
of the tank.
e) Inspect the clean-out gasket, if it shows signs of wear, a new gasket is
required.
• Black water can be an indication of organic contaminates in the water
supply. This can be problematic in areas where the water is obtained from
surface or contaminated sources. Organic particles can develop bacterial
growth, causing potential health hazards. Contact your water supplier for
proper filtration or water conditioning equipment. For bacterial problems
contact your local health authority. Also see ‘Hot Water Odour’ section.
• A sudden appearance of rusty water can indicate the anode rod has been
depleted. The remaining steel core wire may be corroding, releasing iron
particles into the water. Inspect and replace as necessary. Also see
‘Cathodic Protection: Anode Maintenance’ section.
WATER HEATER MAKES NOISE
Sediment, sand or scale can accumulate resulting in “rumbling” or a
“hissing” noise. Water heaters need to be flushed regularly to minimize
buildup. Severe accumulations can cause premature failure of the water
heater elements.
f) Install the clean-out plate. Be sure to draw plate up tight by tightening
screws securely.
g) Position the insulation, and replace the door.
EXTENDED NON USE SERVICE
CAUTION Hydrogen gas is 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. 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.
TROUBLE-SHOOTING
Follow the preceding instructions carefully and your heater should provide
long and trouble free service. If problems do arise however, the following will
be of assistance.
NOT ENOUGH OR NO HOT WATER
1. Make sure the electrical supply to the water heater is “ON”.
2. Check for loose or blown fuses and loose connections in the water heater
circuit.
3. If the water was too hot and is now cold, the high limit temperature switch
may have operated. To reset this, proceed as follows:
a) Turn the electrical supply to the water heater “OFF”.
b) Remove the access door then turn back the insulation.
c) Reset the control by pushing in the red button marked ‘RESET’.
d) Repack the insulation then replace access door.
e) Turn the electrical supply to the water heater “ON”.
4. The capacity of the tank may have been exceeded by large demands of hot
water. Wait at least one hour then check for hot water at normal hot water
faucet.
5. The incoming cold water may be colder because it is winter. If so, it will
take longer to heat the water.
6. If none of the above result in adequate hot water, call a service person.
7. If there is no HOT water, check the upper element.
8. If there is limited HOT water, check the lower element.
9. If water is LUKEWARM check for proper incoming voltage.
WATER LEAKAGE IS SUSPECTED
1. Check all pipes and fittings for leaks, including the drain valve, element(s)
and relief valve.
2. See if the apparent leakage might be condensation. In warm or humid
locations, condensation can accumulate and run from the heater and
piping.
3. If leakage is from the relief valve discharge pipe, it may represent a
normal condition. Call a service person to check the valve carefully.
4. If you cannot identify or correct the source of leakage:
a) Turn off electrical supply to he heater.
b) Close the cold water inlet valve to the heater.
c) Open a hot water faucet.
d) Contact a qualified plumber or service person.
WATER IS TOO HOT
Adjust the thermostats to a lower setting. See ‘Temperature Adjustment’
section. It is imperative that the thermostat is flush against the tank. See
‘Thermostat Replacement’ section.
3
Download from Www.Somanuals.com. All Manuals Search And Download.
PRESSURE BUILD-UP (THERMAL EXPANSION)
During the heating cycle of the water heater, the water expands creating a
pressure build-up in the plumbing system. If the pressure exceeds 150 PSI,
water will come out of the valve. This is a normal safety function of the
T&P valve. The water supply meter may have a check valve or back flow
preventer inside. This can increase the possibility of pressure build-up.
Causes of discharge can be thermal expansion, excess system pressure, too
high a temperature setting on the thermostat or something in the water
heater causing excess temperatures in the heater.
Thermal Expansion: When water is heated it expands. For example, in a
40-gallon water heater, water being heated to its thermostat setting will end
up expanding by approximately 1/2 gallon. This extra volume created by the
expansion has to go somewhere or pressure will dramatically increase, such
as when water is heated in a closed system. A good indication of thermal
expansion is when the T&P valve releases about one cup of water for every
10 gallons of heater capacity with each heating cycle. The T&P valve is
functioning properly when it relieves pressure caused by thermal expansion,
but frequent relief can result in a build up of natural mineral deposits on the
valve seat, rendering the valve inoperative. Should this happen, the T&P
valve needs to be replaced.
To prevent this ‘T & P VALVE’ from discharging hot water, the loss of
energy and reduce the possible build-up of lime in the ‘T & P VALVE’
there are two (2) recommendations:
OPTION 1: Install a 125 PSI Pressure Relief (only) valve in the cold
water supply line. Make sure that the discharge of this valve is directed
to a drain to prevent water damage and it is protected from freezing,
OR
OPTION 2: Install an expansion tank on the cold water supply line.
For every 50 U.S. gallons of stored water, the expansion tank must
have a minimum capacity of 1.5 U.S. gallons.
Temperature Relief: The T&P valve will discharge varying amounts
of water, but typically more than you would experience from thermal
expansion. Check the temperature in relation to the setting on the
thermostat dial. A malfunctioning thermostat could cause the water to
get too hot.
Alternate location of pressure relief valve
OPTION 2
Location of pressure relief and \ or expansion tank if a check valve or
pressure reducing valve is in the cold water supply to the house.
Use option 1 or 2 as convenient. If a pressure relief valve is used
(OPTION 1) select one with a setting 25 psi below the relief valve
rating used on the heater.
OPTION 1
SPACESAVER™ MODELS
(SIDE OUTLET) ONLY
NOTE TO INSTALLERS:
A bent tube (as shown) is installed for the hot water
outlet on side outlet water heaters to ensure a
maximum of hot water supply.
This fitting must be aligned properly.
The ‘line’ on the fitting must be oriented pointing
up. When in correct position, the hot water is drawn
from the highest point in the tank.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Cold water inlet
Hot water outlet
Anode(s)
Temperature and pressure relief valve*
Thermostat
Element
Access door – not illustrated
Floor drain
Drain valve
10. Water supply to meter
11. Water supply to home
12. Water meter with backflow preventer
13. Overflow
14. Pressure relief valve
15. Expansion tank
*Items to be supplied by installer
Refer to pressure relief \ expansion tank
schematic above.
Tee fitting and drain valve
4
Download from Www.Somanuals.com. All Manuals Search And Download.
~ Certificate of Warranty ~
Warranty Code: P R S T U V W
Y
See Rating Label Serial Number prefix for
Warranty Code. Reduced warranty period
applies to Newfoundland.
Standard Warranty Years: 3 5 6 7 8 9 10 12
Reduced Warranty Years: 2 3 3 5 5 5
5
7
For its GSW and John Wood water heaters and storage boosters ("Unit"), GSW Water Heating ("GSW") warrants that,
upon receipt of a properly verified Warranty claim within the Warranty Period, it will, at its election, repair or replace: units which leak; parts which are
defective in material or workmanship, subject to the terms and conditions set forth in this certificate. GSW Units/parts must be replaced with GSW or
John Wood product to be eligible for Warranty. This Warranty is available to the original owner for a Unit installed within the boundaries of continen-
tal United States, 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, which
warranty GSW will make available, to the extent permitted by the manufacturer, without recourse to GSW.
THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF. THIS
EXPRESS WARRANTY IS, WHERE PERMITTED BY LAW, IN LIEU OF AND EXCLUDES AND REPLACES ALL OTHER
CONDITIONS, WARRANTIES, GUARANTEES, REPRESENTATIONS, OBLIGATIONS OR LIABILITIES OF GSW OF
ANY NATURE OR KIND, EXPRESS OR IMPLIED, HOWEVER ARISING (WHETHER BY CONTRACT, CONDUCT,
STATEMENT, STATUTE, NEGLIGENCE, PRINCIPLES OF MANUFACTURER'S LIABILITY, OPERATION OF LAW OR
OTHERWISE) WITH RESPECT TO THE UNIT OR ITS FITNESS FOR A PARTICULAR PURPOSE, MERCHANTABILITY,
INSTALLATION, OPERATION, REPAIR OR REPLACEMENT. GSW EXPRESSLY DISCLAIMS ANY AND ALL IMPLIED
WARRANTIES. IN NO EVENT WILL GSW'S LIABILITIES EXCEED THE COST OF THE DEFECTIVE PART(S) NOR
LEAKING INNER TANK. GSW WILL NOT PAY FOR ANY TRANSPORTATION, LABOUR, INSTALLATION, OR OTHER
INCIDENTAL COSTS ASSOCIATED WITH THE REPAIR OR REPLACEMENT OF A DEFECTIVE PART OR HEATER.
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 of this Warranty 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.
LIABILITY OF GSW COVERED BY THIS WARRANTY IS CONDITIONAL UPON THE FOLLOWING:
1. The Unit shall be installed in accordance with all manufacturers'
instructions, all applicable equipment and building codes, ordinances
and regulations.
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 drainpipe. As all Units 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.
7. A properly documented claim shall be received by GSW or one of its
authorized dealers, or point of purchase:
a) for any defective part within one (1) year; and
b) unless otherwise specified below *, for any leaks that may
occur in the Unit's inner tank due to rust, corrosion or other
chemical reactions caused by the domestic water supplied
to your home, within the period of time shown in table;
*The following are the modified Warranty Periods applicable to
leaks in inner tanks:
*Residential units installed and used in a commercial application
carry a reduced warranty period of one (1) year from date of
installation. 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.
3. The Unit shall not be installed where it will be exposed to adverse or
unusual environmental or corrosive conditions. For example, no
warranty extends to Units exposed to: salt; chemicals; exhausts;
pollutants or contaminants. Further, no warranty extends to Units
affected by fire, freezing or flood, "Acts of God", nor 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 codes. 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 shown on the
Unit.
5. The Unit must be carefully inspected, maintained, and operated in
accordance with the manufacturer's instructions. For example, no
warranty extends 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 salt, 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 qualified personnel who are certified to
work on the Unit, using factory approved replacement parts, and the
Unit shall not be otherwise modified, altered or improperly repaired.
GSW will not assume any expense or liability for unauthorized returns,
nor repairs made by unqualified personnel who are not certified to work
on the Unit.
8. A claim under this Warranty including 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 within
15 days, following discovery of the defect(s), by personal delivery to a
GSW authorized dealer, point of purchase, or contact GSW itself at:
Technical Support Line 1-800-447-6575 ext 2
Address: GSW Water Heating
A GSW Inc. Company
599 Hill Street West
Fergus, ON Canada N1M 2X1
9. If requested by GSW, information relating to the purchase,
transportation operation and installation of the Unit shall 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 request.
All claims are subject to validation by GSW.
5
Download from Www.Somanuals.com. All Manuals Search And Download.
|