GSW POWER VENTED GAS FIRED WATER HEATER Installation And Operating Instructions Manual Download Page 2

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TABLE OF CONTENTS

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

User

Responsibilities

Qualified Installer Or Service Agency

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Safety Warning (Flammable Vapours)

Safety Warning (Scalding)

Safety Warning (Carbon Monoxide)

Relief Valve Requirements (T&P)

Flooding/Freezing/Fire

Damage

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Unpacking the Water Heater

Location

Requirements

In Earthquake Zones

Closet

Installations

Floor

Surfaces

Clearances

and

Accessibility

Gas

Supply

Gas Supply Pressure

Gas

Leak

Testing

Gas Operating Pressures

Air

Requirements

Appliances In Enclosures

Typical

Installation

Replacement Parts And Deliming Products

Water Piping - Mixing Valve Usage

Mixing

Valves

Exhaust

Venting

High

Ambient

Temperature

Installations

Important Notes and Warnings

Venting Terminations and Sizing

Rodent

Screens

Calculating Equivalent Feet

Venting

Instructions

Blower Exhaust Direction

Blower

Assembly

Installation

Vent Pipe Connection to Blower

Condensate

Water

Supply

Piping

Installation

Filling the Water Heater

Closed System/Thermal Expansion

Temperature and Pressure (T&P) Relief Valve 18

The Temperature and Pressure Relief Valve:

The Discharge Line/Relief Drain Tube:

Temperature-Pressure Relief Valve and Pipe
Insulation

Electrical

Supply

SAFETY LOCKOUTS . . . . . . . . . . . . . . . . . . . . . . . .21

High Limit Controls

Thermostat/Water

Temperature

Blower Exhaust Gas Limit Switch

Blower Air Pressure Switch

Flammable Vapour Sensor

Resettable

Lockout

Water Heater Operation

Installation

Checklist

OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . .23

Temperature

Regulation

Mixing

Valves

Lighting

Instructions

Operating The Temperature Control System

Gas Control Valve/Thermostat

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Burner

Flames

Operational

Conditions

Condensation

Water Heater Sounds

Smoke/Odour

Anode Rod/Water Odour

“Air” In Hot-water Faucets

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Draining and Flushing

Routine Preventative Maintenance
(Homeowner/User) 27

Gas

Control

Temperature and Pressure Relief Valve

Burner Operation and Inspection

Burner

Cleaning

Housekeeping

Anode Rod Inspection

To Remove the Anode Rod

To Install the Anode Rod

Venting System and Blower

COMBO HEATING . . . . . . . . . . . . . . . . . . . . . . . . . . .31

System

Requirements

Installation

TROUBLESHOOTING

GUIDE

. . . . . . . . . . . . . . . . . .32

ECO

Reset

Ignition State and Timing

System Error Codes

Honeywell Troubleshooting Chart -
User Control

REFERENCE PARTS . . . . . . . . . . . . . . . . . . . . . . . .36

Reference Parts Listing

LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . .38

RETAIN THESE INSTRUCTIONS IN A SAFE LOCATION FOR FUTURE REFERENCE

– 2 –

Summary of Contents for POWER VENTED GAS FIRED WATER HEATER

Page 1: ...on in these instructions is not followed exactly a fire or explosion may result causing property damage per sonal injury or death 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 WH...

Page 2: ... Relief Valve The Discharge Line Relief Drain Tube Temperature Pressure Relief Valve and Pipe Insulation Electrical Supply 19 SAFETY LOCKOUTS 21 High Limit Controls 21 Thermostat Water Temperature Blower Exhaust Gas Limit Switch Blower Air Pressure Switch 21 Flammable Vapour Sensor 21 Resettable Lockout 21 Water Heater Operation 21 Installation Checklist 22 OPERATING INSTRUCTIONS 23 Temperature Re...

Page 3: ... combination with space heating applications User Responsibilities This manual has been prepared to acquaint you with the installation operation and maintenance of your gas 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 RES...

Page 4: ...mable 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 DANGER Hot water produced by this appliance can cause severe burns due to scalding The hazard is increased for young children the age...

Page 5: ...er and your safety Since we cannot put everything on the first few pages READ ENTIRE MANUAL BEFORE ATTEMPTING TO INSTALL OR OPERATE THE WATER HEATER After installation dispose of packaging material in the proper manner Location Requirements IMPORTANT This water heater must be installed strictly in accordance with the instructions enclosed and all applicable electrical fuel and building codes It is...

Page 6: ... if in an alcove or closet installation the entire floor must be covered by the panel Clearances and Accessibility DO NOT BLOCK AIR INTAKE OR SENSOR ACCESS ENSURE ADEQUATE CLEARANCE FOR AIR SUPPLY FRONT 600mm 24 in MIN FOR SERVICE BACK AIR INTAKE SENSOR SIDES ALCOVES SIDES TOP TO CEILING CLOSETS Figure 2 DRIP LEG MANUAL GAS SHUT OFF GAS CONTROL THERMOSTAT GROUND JOINT UNION 76mm 3 in Figure 3 The ...

Page 7: ...ss than 14 in w c 3 5 kPa the water heater must be isolated from the gas supply piping system by closing its manual shut off valve 1 2 3 4 WARNING Exposure to a higher gas supply pressure may cause damage to the control resulting in explosion or fire Consult your local gas supplier and gas authorities DO NOT PUT INTO SERVICE IF OVER PRESSURIZATION HAS OCCURRED Gas Operating Pressures The gas suppl...

Page 8: ...ir Tubing see Figure 9 26 Rubber Coupling 27 Gear Clamp 28 Flue Collector 29 Hot Water Outlet Nipple 30 Anode under cap 31 Cold Water Inlet Nipple 32 Flexible Manifold Tube see Figures 6 7 33 Viewport see Figures 6 7 34 Flame Sensor Rod see Figures 6 7 35 Gas Orifice see Figures 6 7 36 Sheet Metal Burner see Figures 6 7 37 Gas Manifold see Figures 6 7 38 Hot Surface Igniter see Figures 6 7 39 Mani...

Page 9: ...ed as the primary water inlet and outlet connections For your convenience plugs are installed in these fittings at the factory Remove these plugs if needed for your specific installation Otherwise as with all connections check for leaks while filling the tank with water and after completing the installation Caution harness has 120 VAC present during opera tion Replacement Parts And Deliming Produc...

Page 10: ...METAL DRAlN PAN 150mm 6 MAX AIR GAP TO SUITABLE DRAIN NOTE THE T P VALVE CAN BE PIPED DIRECTLY TO THE DRAIN Figure 12 Mixing Valves Water heaters are intended to produce hot water Water heated to a temperature which satisfies space heating clothes washing dish washing and other sanitizing needs can scald and cause permanent injury upon contact Short repeated heating cycles caused by small hot wate...

Page 11: ... can experience high ambient environments include closets alcoves areas under staircases attics especially in metal roofed buildings areas with restricted air movement rooms with large solar gains metal sheds industrial or commercial enterprises and venting systems exposed to direct sunlight For high temperature environments obtain high limit switch upgrade Kit 9008306015 and use the higher rated ...

Page 12: ...r less VENT LENGTH LESS THAN OR EQUAL TO 20 EQUIVALENT FT 6 1 METRES USE THIS SCREEN SUPPLIED VENT LENGTH GREATER THAN 20 EQUIVALENT FT 6 1 METRES USE THIS SCREEN SUPPLIED Figure 14 Rodent Screens A vent termination screen is required to keep foreign objects rodents and small birds from entering the venting system These screens have been sized to ensure maximum energy efficiency of the vent system...

Page 13: ...lene Vent Pipe Size Elbow Type Short Sweep Short Radius Long Sweep Long Radius Notes 1 Use long radius elbows where possible Minimum distance between 90º elbows should be 6 150mm wherever possible 2 Venting systems may use a maximum of five 5 90 elbows 3 Use proper screen termination see Figures 14 15 2 3 4 90 8 ft 2 44m 5 ft 1 52m 2 3 4 45 4 ft 1 22m 2 5 ft 0 76m Table 1 Example for calculating e...

Page 14: ...ent piping to ensure adequate drainage Horizontal vent pip ing must not sag to form valleys where condensate may collect Vertical venting shall be supported every 1 5m 5 ft CAUTION Use of Solvent Cement and Primer Use only in well ventilated areas Do not use near flame or open fire Use only the Solvent Cement and Primer appropriate for the venting material being used Solvent cements for plastic pi...

Page 15: ...e sure the plastic tubing is not folded anywhere between the pressure switch and the blower housing 5 This water heater is a polarity sensitive appliance and will not operate if the power supply polarity is reversed Power to this water heater must be wired properly cor rect polarity 6 Do not plug in power cord until vent system is complete ly installed The Power Vent operates on 110 120 VAC theref...

Page 16: ...piping is firmly secured in the coupling and is gas tight Do not over tighten or cause distortion of any of the parts Ensure the bottom of the rubber coupling is firmly seated on the blower outlet and that the lower gear clamp is also secure Check to ensure there is no distortion or move ment of the clamped assembly once it is completed BLOWER 2 VENT PIPE 2 RUBBER COUPLING SUPPLIED CONFIGURATION F...

Page 17: ...TS 200mm 8 in LOOP TO DRAIN BLOWER ASSEMBLY Figure 26 Water Supply Piping Installation Piping fittings and valves should be installed according to the installation drawing Figure 27 Water supply pressure should not exceed 550 kPa 80psi If this occurs a pressure reducing valve and or an expansion tank may be required The pressure reducing valve should be placed on the supply to the entire house in ...

Page 18: ...RING VALVE SET TO 49 C 120 F FOLLOW THE TEMPERING VALVE MANUFACTURER S INSTRUCTIONS T P VALVE AND DISCHARGE LINE COLD WATER TEMPERED WATER TO FIXTURE Figure 28 Closed System Thermal Expansion Water supply systems may because of code requirements or such conditions as high line pressure among others have installed devices such as pressure reducing valves check valves and back flow preventers Device...

Page 19: ...tely close the cold water inlet to the water heater follow the draining instructions in this manual and replace the temperature pressure relief valve with a properly rated sized new one Temperature Pressure Relief Valve and Pipe Insulation The T P valve installed on this water heater is covered by insulation to minimize heat loss The insulation has a hole on the bottom side to accommodate the valv...

Page 20: ... Verify proper opera tion after servicing Note Always reference the wiring diagram for the correct electrical connections WARNING When the unit is plugged in 120VAC is pres ent at the electric connections of the gas control thermostat 1 27 685 1 7 5 80 85 0 7 6 7 0 7 85 7 03e5 785 3 725 21 16 7 85 57 1 0 7 35 6685 6 7 35 66267 7 2 5 628 5 0 6 1625 e7 7 85 00 6 00 9 3285 6 1625 e7 7 85 9 3 856 1 00...

Page 21: ...control will flash the gas lockout code Refer to the System Error Codes section of this manual for an explanation of the codes applicable to the control installed on your water heater If this error occurs check around the water heater for sources of chemical contamination such as flammable vapours including gas vapours solvents paint and thinners as well as sources of water and detergents Remove a...

Page 22: ... possible gas leaks Vent Pipe System 1 Vent pipe and fittings of approved material 2 Acceptable size length and number of elbows on exhaust vent system 3 Installed in accordance with the latest edition of Natural Gas and Propane Installation Code CSA B149 1 4 Horizontal piping slopes at a pitch of 3mm 1 8 in rise per 1 2m 4 ft 5 Not obstructed in any way Check Here Vent Termination Horizontal 1 30...

Page 23: ...Feel water before bathing or showering Temperature limiting valves are available Mixing Valves Hot water can scald Water heaters are intended to produce hot water Water heated to a temperature that will satisfy space heating clothes washing dish washing and other sanitizing needs can scald and permanently injure you upon contact Some people are more likely to be permanently injured by hot water th...

Page 24: ...sition 9 Turn thermostat to desired setting DANGER Hotter water increases the risk of scald injury Consult the instruction manual before changing temperature 10 If the appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier OPERATING INSTRUCTIONS DANGER A This appliance does not have a pilot It is equipped with an ignition de...

Page 25: ...he water heater Mixing valves are available at plumbing supply or hardware stores see Figure 11 12 Follow manufacturer s instructions for installation of the valves Before changing the factory setting on the thermostat in this manual see Table 3 The water heater should be located in an area where the general public does not have access If a suitable area is not available a cover should be installe...

Page 26: ...d should be considered normal 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 1 2 3 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 ...

Page 27: ...g Presence of flammable or corrosive materials in the installation area Presence of combustible materials near the water heat er Verify proper operation after any service is performed on this water heater Gas Control There are no user serviceable parts in this control The control is supplied with tamper resistant screws DO NOT attempt to repair or adjust the control If you experience problems disc...

Page 28: ...r supply proper clearances from the water heater must be maintained See Locating the New Water Heater section Combustible materials such as clothing cleaning materials or flammable liquids etc must not be placed against or adjacent to the water heater which can cause a fire Anode Rod Inspection Each water heater contains at least one anode rod which will slowly deplete due to electrolysis prolongi...

Page 29: ... so you can access to the anode head Figure 39 Keep in a safe place for reinstallation later Remove the anode rod by using a ratchet and a 1 1 16 socket turning counter clockwise Figure 39 1 2 3 4 5 6 7 To Install the Anode Rod Use Teflon tape or an approved pipe sealant on threads of the new anode rod Place the anode rod in the spud top of the tank and turn clockwise until the threads are hand ti...

Page 30: ... blower wheel This can be problematic especially where condensation is present as particles may adhere to the venting sur faces These conditions can result in nuisance failures In areas that have a high level of airborne particulate e g lint sawdust process smoke laundry areas etc inspection and cleaning may need to be done more fre quently The blower wheel and venting must be cleaned as required ...

Page 31: ...eventer in the cold water line an expansion tank of adequate size must be installed Combo Heating Systems require higher water tem peratures than other applications When the system is used to supply water for Combo Heating applications a means such as mixing valve must be installed to temper the water in order to reduce scald hazard potential see Figures 42 43 Installation The heating mode may be ...

Page 32: ...ry air Low gas pressure Orifice too small Thermostat set too low Heater too small Wrong piping connection Wasted hot water Flue clogged Air inlets blocked 1 2 3 4 5 6 7 8 9 Provide ventilation to water heater Check flue way flue baffle and burner Check with gas utility company Replace with correct orifice Turn temperature knob to higher setting Install adequate heater Correct piping dip tube must ...

Page 33: ... treatment if needed Refer to Condensate section 1 2 WATER LEAKAGE Condensation Dripping Temperature Pressure Relief Valve Thermostat does not shut off Drain valve dripping leaking Tank Leak 1 2 3 4 5 Refer to Condensate section Refer to Temperature Pressure Relief Valve section Check the Thermostat Back flush to clean out sediment replace if necessary Check Leakage Checkpoints 1 2 3 4 5 BLOWER WI...

Page 34: ...ip requires manual intervention and can not be reset by cycling power to the control A manual reset requires turning the temperature setting dial to the lowest coldest position for a minimum of 10 seconds and then returning it to the desired setpoint Amanual reset is allowed after each of the first two ECO trips After a third ECO trip the control enters a hard lockout state Ignition State and Timi...

Page 35: ...ght dim Call For Heat no fault conditions One Flash three second pause Low Flame Signal control continues to operate Two Flash three second pause Pressure Switch Failed Closed Three Flash three second pause Pressure Switch Failed Open Four Flash three second pause TCO Limit Lockout Five Flash three second pause Flame Out Of Sequence Six One Flash three second pause Soft Lockout Retry Limit Failed ...

Page 36: ...g System Return Inlet Optional 19 Air Inlet Snorkel 20 Combo Heating System Supply Outlet Optional 21 Blower with Power Cord see Figure 49 22 Air Switch inside box see Figure 49 23 Junction Box see Figure 49 24 Junction Box Cover see Figure 49 25 Air Tubing see Figure 49 26 Rubber Coupling 27 Gear Clamp 28 Flue Collector 29 Hot Water Outlet Nipple 30 Anode under cap 31 Cold Water Inlet Nipple 32 F...

Page 37: ...35 40 41 Natural gas and Propane main burner with igniter assembly for 60k to 75k Btu hr models Flare Nut Figure 47 17 Figure 48 25 23 24 22 5 26 27 Figure 49 Notes Natural gas models have Right hand thread Propane models have Left hand thread For Natural gas models the Flare Nut has Right hand thread For Propane models the Flare Nut has Left hand thread 37 ...

Page 38: ...he water heater s Model Number SKU Serial Number date of purchase and date of installation c 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 THE MANUFACTURER OF ANY NATURE OR KIND EXPRESS OR IMPL...

Page 39: ...r contingency beyond the control of the Manufacturer or s The water heater is installed in a closed system without adequate provision for thermal expansion 3 Except when speci cally prohibited by the applicable law the Owner and not the Manufacturer shall be liable for and shall pay for all charges for labour or other expenses incurred in the removal repair or replacement of the water heater or an...

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