GSW Water Heater POWER VENTED GAS FIRED WATER HEATER User Manual

GSW WATER HEATING COMPANY  
599 HILL ST. WEST, FERGUS, ONTARIO N1M 2X1  
CANADA  
®
“SUPERFLUE”  
POWER VENTED GAS FIRED WATER HEATER  
INSTALLATION AND OPERATING INSTRUCTIONS  
Read these instructions  
WARNING: If the information in these instructions is  
- Installation and service must be performed by a  
not followed exactly, a fire or explosion may result  
-WDAoRnNoINt sGt:oIrmeporroupsereignsatsaolllainieono,raodtjuhsetrmfleanmt,mable  
qualified installer, or the gas supplier.  
alteration, service, or maintenance can cause injury or  
causing property damage, personal injury or death.  
vapors and liquids in the vicinity of this or any  
property damage. Refer to this manual. For  
other appliance.  
assistance or additional information, consult a  
- WHAT TO DO IF YOU SMELL GAS  
qualified installer, service agency, or the gas supplier.  
· 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.  
thoroughly before starting  
TABLE OF CONTENTS  
I) Introduction .........................................................................................................2  
II) Air Requirement.................................................................................................................................4  
III) Venting............................................................................................................................................7  
IV) Water Piping.................................................................................................................................. 10  
V) Gas Piping...................................................................................................................................... 10  
VI) First Lighting.....................................................................................................................................................................11  
VII) Service And Maintenance................................................................................................................................................14  
VIII) Combo Heating..................................................................................................................................................................16  
IX) Troubleshooting.............................................................................................................................. 18  
X) Warranty...................................................................................................................................... 19  
This Manual Applies to Electronic Ignition Power Vented Water Heater  
Check The Specific Venting Label On The Water Heater For Details  
PLEASE RETAIN THESE INSTRUCTIONS IN A SAFE LOCATION FOR FUTURE REFERENCE  
PART NO. 50000 REV. ¬ (FF-06-99)  
 
I) Introduction  
All electrical connections shall be in accordance with the latest  
edition of the Canadian Electrical Code CSA C22×1 Part 1.  
We thank you for choosing a GSW/ John Wood Water Heater.  
Your satisfaction with this product is very important to us.  
U.S. Installations  
This gas-fired water heater has been developed to produce  
potable hot water and may also be used in combination with space  
heating applications. The “Superflue”Ô series is designed to vent  
the products of combustion (flue gases) horizontally through an  
exterior wall or vertically through the roof using an integrated  
blower assembly and plastic piping, without the need for a  
conventional chimney.  
In addition to the installation instructions found in this manual,  
the heater shall be installed in accordance with the latest edition  
of the National Fuel Code ANSI Z223×1 (NFPA 54) and/or any  
local codes. These shall be carefully followed in all cases.  
Authorities having jurisdiction shall be consulted before  
installations are made.  
Important: All supply equipment, installation, Approvals,  
permits, inspections, etc. are the responsibility of the owner of  
this water heater. Consult your local authorities for regulations  
specific to your area.  
Important Consumer Notice  
These instructions have been written for the proper installation,  
safe operation and maintenance of this water heater.  
It is your responsibility to ensure that your water heater is  
properly installed and cared for. FAILURE TO FOLLOW  
THE INSTRUCTIONS IN THIS MANUAL MAY  
RESULT IN SERIOUS BODILY INJURY AND /OR  
PROPERTY DAMAGE. THOROUGHLY READ ALL  
INSTRUCTIONS before you attempt to install or operate this  
heater.  
Relief Valves (T&P)  
All heaters must be installed with a proper temperature and  
pressure relief valve. These valves must be certified as meeting  
the requirements for Relief Valves and Automatic Gas Shut-Off  
Devices for Hot Water Supply Systems, ANSI Z21×22 in the  
United States. When in Canada, the Standard for Temperature,  
Pressure, Temperature and Pressure Relief and Vacuum Relief  
CAN 4×4 is required.  
Installation and service require trade knowledge in the area of  
plumbing, electricity, venting, air supply and gas supply. If you  
lack these skills or do not understand these instructions, enlist  
the help of a qualified professional.  
Backflow Prevention  
Certain jurisdictions may require the installation of a backflow  
device (e.g., check valve) in the water supply line. Such a device  
will require the use of a system expansion tank of adequate size  
to control the thermal expansion generated during the heating  
cycle. Consult your water supplier or local plumbing authority.  
GSW Water Heating Company, the manufacturer of this water  
heater, cannot be held liable for those damages caused by  
improper installation, sizing or failure to comply with these  
instructions.  
Important: The supply water meter may have a built-in check  
valve device. Contact your local water authority.  
Approvals  
This water heater has been certified for operation using natural  
gas or propane gas fuel by the Canadian Gas Association (CGA)  
and design-certified by the American Gas Association  
Laboratories (AGA) through International Approval Services Inc.  
This heater is approved to provide potable hot water or when  
combined with a suitably-sized fan coil, baseboard heater, etc., to  
provide both space heating and domestic hot water.  
Safety Warnings  
Ø
Water Heaters are heat-producing appliances. To avoid  
damage or injury, no materials shall be stored against the  
heater and provision shall be made to prevent unauthorized  
contact (e.g. children).  
FOR YOUR SAFETY, DO NOT STORE OR  
USE GASOLINE OR OTHER FLAMMABLE,  
COMBUSTIBLE OR CORROSIVE VAPORS  
OR LIQUIDS IN THE VICINITY OF THIS  
HEATER OR ANY OTHER APPLIANCE.  
Installation Code Requirements  
Canadian Installations  
In addition to the installation instructions found in this manual,  
the heater shall be installed in accordance with the latest edition  
of CAN/CGA B149.1, B149.2 installation codes and/or any local  
codes. These shall be carefully followed in all cases. Authorities  
having jurisdiction shall be consulted before installations are  
made.  
Ø
Hot water produced by this appliance can cause severe burns  
due to scalding. The hazard is increased for young children,  
-2-  
 
the aged, or the disabled where water temperatures exceed  
125° F (52°C).  
Use anti-scald valves in the hot water system to reduce the  
risk of scalding at points 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.  
(softener salt) or other process chemicals are typical of  
compounds which are potentially corrosive.  
Ø
Products of this type should not be stored near the heater.  
Air containing these chemicals should not be used as supply  
to the heater. If necessary, uncontaminated air shall be  
obtained from remote or outside sources.  
Ø
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  
recirculation of the exhaust flue gases. Such a condition can  
cause sooting or present a fire hazard, which may result in  
serious bodily harm or death from asphyxiation.  
Ø HYDROGEN GAS CAN BE PRODUCED IN A  
HOT WATER SYSTEM. THIS CAN BE  
PROBLEMATIC IN SYSTEMS WITH LONG  
STANDBY PERIODS. 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. 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 THAT IT IS OPEN.  
MAKE SURE THE FLOW OF COMBUSTION  
AND  
VENTILATION  
AIR  
IS  
NOT  
RESTRICTED.  
Ø
If this water heater has been exposed to flooding, freezing,  
fire or any unusual condition, do not put it into operation until  
it has been inspected and approved by a qualified  
professional. THESE CONDITIONS CAN RESULT  
IN UNSEEN INTERNAL DAMAGE and are not  
subject to warranty coverage.  
INSTALLATION INSTRUCTIONS  
NOTICE  
Safety Warnings  
Before installing this water heater consideration and planning  
must be given to the following details:  
Ø
There is a risk in using fuel-burning appliances such as water  
heaters. Areas that may not be suitable for water heater  
installation include those where flammable liquids, gasoline,  
solvents, adhesives, etc., or engine-driven equipment or  
vehicles are stored, operated or repaired. Due to the nature  
of air movement, flammable vapors can be carried some  
distance from the point of storage. The gas-fired water  
heater, pilot or main burner flame can ignite these vapors  
causing a flashback fire or explosion which may result in  
serious personal injury or death, as well as severe property  
damage.  
Ø
Heater location. The vent blower can create air noise. Do not  
install near sleeping area, in a bedroom or bathroom;  
Location of the outside vent terminal; See “Venting” p. 7.  
Routing and support of the vent piping; Figure 5 page 8.  
How and where to obtain combustion and ventilation air  
supply; See “Air Requirements” page 4.  
Position of water supply and placement of water piping for  
hot and cold water; See “Water Connections” page 10.  
Access for gas supply, electrical power, floor drain and  
service. See “Gas Service” pages 10 and 11.  
Ø
Ø
Ø
Ø
Ø
NOTICE  
If installation in a garage or shed is the only option, it is  
recommended that the water heater be elevated a minimum  
of 18" (45 cm) above the floor level. This may reduce BUT  
NOT ELIMINATE the risk of flammable vapors being  
ignited. Such installations must be protected from impact or  
physical damage caused from moving equipment or vehicles.  
REVIEW SAFETY WARNINGS FOUND IN THE  
FRONT OF THIS MANUAL BEFORE PROCEEDING.  
Location and Clearances  
Locate the water heater such that all controls are easily  
accessible. We recommend that 24" (0.6 m) in front of the  
heater and 34" (0.9 m) above be maintained for serviceability.  
Ensure that the water heater is level. See Figure 1. Page 1. and  
Figure 2 page 4.  
CHECK LOCAL CODES!  
Ø
Exposure to air borne chemicals can cause severe corrosion  
to the water heater and damage to the venting parts. Air  
containing vapors from cleaning solvents, pool chemicals,  
refrigerator or air conditioning refrigerants, laundry  
detergents or bleaches, waxes, spray can propellants, dry  
cleaning, photo processing liquids, calcium and sodium chloride  
This heater is designed to safely operate with the following  
minimum clearances to combustibles.  
Front 2" (50 mm) Sides and Rear1" (25 mm)  
Top 12" (305 mm) Plastic Vent Piping 0" (0.0 mm)  
-3-  
 
Locate near a floor drain and in an area where leakage of the tank  
or water piping will not result in damaging adjacent areas or lower  
floors of the structure. Where such a location is not available, a  
suitable drain pan must be installed under this water heater. This  
pan shall be 1½ “ (40 mm) deep and a diameter that is a minimum  
of 2" (50 mm) greater than the diameter of the water heater. A  
suitable pipe properly connected to an adjacent floor drain shall  
be provided.  
II) AIR REQUIREMENTS  
General.  
Ø 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 could create a serious health  
hazard by producing carbon monoxide.  
This heater may be installed in a closet or alcove and is certified  
for operation on a combustible floor.  
WARNING  
Do not install directly on carpet. Instead, place the water heater  
on a metal or wood panel extending a minimum of 3" (75 mm) from  
all sides. In alcoves or closets, cover the carpet completely.  
Ensure that this panel is capable of supporting the weight of this  
heater when filled with water.  
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 operating simultaneously.  
The area in which the heater is located is classified as either “an  
unconfined space” or “a confined space.”  
FAILURE TO PROPERLY INSTALL THIS HEATER  
MAY RESULT IN A FIRE HAZARD.  
An unconfined space is defined as a space 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 space is one smaller than described above. Air shall  
be supplied through permanent openings as described in Figures  
3 and 4. At no time shall an air opening have a dimension of less  
than 3" (75 mm) 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 AREA is never less than the area of the air  
duct.  
-4-  
 
Air Requirements for Canadian  
Installations  
Canadian Codes allow for the use of a single air supply source.  
Canadian customers and authorities having jurisdiction may use  
the sizing listed in Table 1. Check Local Codes.  
When using a single air supply, the duct shall terminate within 1  
foot (30 cm) above and within 2 feet (60 cm) horizontally from  
the burner level of the appliance having the largest input as shown  
in Figure 3 (b), (c) and (d).  
An opening shall be located neither more than 18 inches (450  
mm), nor less than 6 inches (150 mm), above floor level. See  
Figure 3 (b), (c) and (d).  
Two permanent openings 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 input (5.5 cm²/kW) of all appliances in the  
confined space. The top opening shall commence within 12" (30  
cm) of the top of space and the bottom opening shall commence  
within 12" (30 cm) of the bottom of the enclosure. See Figure 3  
(a).  
All exterior vent openings are to be clear of snow levels.  
Table 1  
Combined Input of All  
Appliances in Confined Free Area  
Required  
Acceptable Round  
Duct Size Diameter  
Space*  
A 1  
B 2  
BTU/hr  
25,000  
(KW/hr)  
In.2 cm2 In. mm In. mm  
(8)  
7(45)  
3(75)  
4(100)  
4(100)  
5(125)  
5(125)  
6(150)  
6(150)  
50,000 (15)  
75,000 (23)  
100,000 (30)  
125,000 (37)  
150,000 (45)  
7(45)  
3(75)  
11 (70)  
14(90)  
18(120)  
22(140)  
4(100)  
4(100)  
5(125)  
5(125)  
1 Maximum length of ducts in column A is 20 equivalent feet (6.1  
meters)  
2 Maximum length of ducts in column B is 50 equivalent feet (15.2  
meters)  
* All appliances refers to and includes those appliances using the  
same air source. e.g. Water heater, furnace, boiler, clothe dryer, etc.  
-5-  
 
3. Dry fit all vent pipes, elbows and fittings before joining any  
parts with solvent cement. Use only the recommended  
adhesive for ABS, PVC or CPVC, depending on your  
installation. PARTS MUST FIT WITHOUT STRESS  
OR BENDING OF ANY SECTION, and each  
connection must overlap a minimum of ½” (15 mm). Caution:  
solvent cements for plastic piping are flammable. Use only in  
well ventilated areas and keep away from all sources of  
ignition.  
III) EXHAUST VENTING  
IMPORTANT: READ THIS SECTION BEFORE  
PROCEEDING.  
The SuperflueÔ series is designed to exhaust the products of  
combustion to the outdoors using a sealed vent pipe system.  
Required materials and vent sizing are described in Table 2.  
Refer to figure 6 to determine the exhaust vent termination  
position.  
4. Support the vent piping every 4 feet (1.2 meters) to prevent  
stress or sagging. DO NOT USE AN ELBOW AS A  
SUPPORT POINT. Elbows are not designed to carry the  
weight of the venting system. Use appropriate support straps and  
Plan the layout from the vent terminal back to the water heater.  
Take into consideration piping position, elbows and support.  
vibration isolators on a straight section.  
SUPPORTED VENTING CAN POSE A SAFETY  
HAZARD.  
IMPROPERLY  
Venting Instructions  
1. Refer to Figure 5 and Table 2 for vent pipe materials and  
sizing.  
5. For long runs of venting, or when passing through cold or  
unheated areas, condensation can develop. Slope vent pipe to  
drain through termination outlet. If vertical runs are used, a  
condensate drain should be provided.  
Ø
Ø
Use 45° elbows wherever possible.  
Do not use 90° “back to back” elbows and do not use  
street elbows. Maintain 6" (150 mm) of straight section  
between elbows.  
6. At the point where the vent pipe exits the building, drill a 2½”  
(65 mm) hole for 2" (50 mm) venting or a 3¾” (95 mm) hole  
for 3" (75 mm) venting). See Figure 5.  
Ø
Calculate “Equivalent Vent Length” before starting. Do  
not exceed the values shown in Table 2. Example: The  
water heater is located 12 feet (4 meters ) from the  
desired termination point. To reach this, you determine  
that you need (3) 90° elbows plus about 15 feet (5  
meters) of 2" (50 mm) straight section. From Table 2, it  
is seen that each 2" elbow = 5 equivalent feet (1.5  
meters) Therefore this example uses 30 equivalent feet.  
CAUTION: BEWARE OF ANY CONCEALED  
WIRING OR PIPING INSIDE THE WALL.  
7. Insert the vent pipe through this hole and secure into  
position. Connect the vent pipe terminal elbow as shown in  
Figure 5. Seal around the vent pipe with caulking or silicone  
once the position is finalized. Ensure that the Debris/Rodent  
Screen is properly installed.  
Ø
Important: When using long runs of vent or when passing  
through cold or unheated areas condensation of the  
gases can develop. Provision must be made for a  
condensate trap or drainage.  
Power Vent Connection  
1. The plastic vent piping connects into the rubber coupling on  
the blower assembly. See Figure 7. Lightly sand the end of  
the vent pipe to roughen the outside surface to provide a  
good mechanical connection with the rubber coupling.  
2. Measure vent piping and cut to required lengths, Pipes shall  
be cut at right angles and deburred to ensure a good fit.  
2. Loosen the top clamp on the coupling and insert the end of  
the vent pipe a full 1¼ “ (35 mm). Check that there is no  
stress in the vent pipe system caused by twisting or bending.  
Do not use glue or sealant at this connection.  
3. Tighten top clamp so that the vent pipe is firmly secured in  
the coupling and is gas tight. Do not over-tighten or cause  
distortion of the parts.  
4. Check that the bottom of the coupling is firmly seated on the  
blower outlet and that the bottom clamp is also secure.  
-7-  
 
Ensure that there is no movement of the clamped assembly  
once it is completed.  
water heater and piping system with water. When an  
uninterrupted stream of water flows from the faucet, the  
system is full. Close faucet. Check for leaks and repair as  
necessary.  
IV) Water Pipe Connections  
Water piping and fittings should be installed as shown in Figure  
8.  
7. Connect a hose to the drain valve and connect to drain. Open  
drain and let water run until clear to flush out any foreign  
1. Close main water supply and drain the piping system where  
water heater is to be connected.  
2. Water heater “inlet” and “outlet” are identified in the top  
cover (see figure 8).  
3. When attaching solder (sweat) fittings, DO NOT APPLY  
HEAT DIRECTLY TO THE WATER HEATER  
NIPPLES or the plastic liners will be damaged. Sweat  
adapters to the first section of the water piping before  
threading onto the water heater.  
4. Install a manual shut-off valve in the cold water supply line.  
It is good plumbing practice to include unions at the hot and  
cold connections as shown. (Fig. 8)  
5. IMPORTANT: Before putting the water heater into  
service, make sure that a properly rated and sized  
temperature and pressure relief valve is installed in the  
designated fitting in the water heater. The relief pressure  
marked on the relief valve must not exceed that stated on  
the rating plate of the water heater.  
matter that may have entered the system. Once flushed,  
close the drain valve and disconnect hose.  
IMPORTANT: The relief valve must be connected to a  
discharge or drain pipe no smaller in size than the outlet of  
the relief valve. This pipe must not be valved, plugged,  
allowed to freeze, or be restricted in any way. Terminate  
close to a drain of adequate capacity.  
V) Gas Service  
The relief valve is necessary to avoid excessive water  
pressure or water temperature from developing. Such a  
condition could cause serious personal injury due to scalding  
or serious physical damage to the water heater. This safety  
device shall be checked annually for proper operation.  
Gas piping and fitting shall be installed as shown in Figure 9.  
Check that a properly sized gas meter and regulator are available  
to service the water heater. If other appliances are using the  
same meter and regulator, ensure that the capacity of the meter  
and regulator matches that of the combined input of all  
appliances connected to it. The gas control supplied with this  
water heater is designed for a maximum inlet pressure of 0.5  
p.s.i. (14" water column).  
Check local Codes.  
6. With water piping installed, check that a hot water faucet  
served by the water heater is open and that the heater drain  
valve is closed. Open the cold water supply valve and fill the  
-8-  
 
WARNING  
Exposure to a higher gas supply pressure may cause damage to  
the control, resulting in explosion or fire. Consult your local gas  
supplier and gas authorities. DO NOT PUT INTO SERVICE  
IF OVER-PRESSURIZATION HAS OCCURRED.  
Use gas piping of adequate sizing to ensure full gas input. All  
piping must comply with all local codes. In the absence of local  
codes, piping must comply with the rules stated by the applicable  
National Fuel Gas Codes. Final connection to the water heater is  
made using 1/2" N.P.T. pipe.  
A manual gas shut-off valve shall be installed in the gas line  
near the water heater. A union is recommended for ease of  
service.  
must meet the minimum provisions as stated in the National  
Electrical Code for U.S. customers and in the Canadian Electrical  
Code for Canadian customers.  
To trap dirt or foreign material in the gas supply, a dirt (drip)  
leg shall be installed in the piping.  
The electrical controls used inside the thermostat/gas valve  
mounted on this water heater is polarity sensitive. Ensure that  
the electrical supply is properly connected in the receptacle box.  
Failure to connect properly will cause the unit not to function (See  
Figure 10).  
Apply joint compound (pipe dope) to the male ends of the  
threads before joining pipe sections. Use only compounds  
that are compatible with natural gas and propane fuels. To  
prevent damage to the gas valve, do not over-tighten.  
Purging  
Caution:  
Gas line purging is required to eliminate air from the piping  
system. Purging should be performed by persons experienced in  
this type of gas service. Do not purge in confined areas or space  
where ignition may occur. To avoid risk of fire or explosion ensure  
the area is well-ventilated and all sources of ignition are de-  
activated. Contact your local gas authority for local requirements.  
IMPORTANT: Disconnect the water heater from the gas  
piping during any high pressure testing above 0.5 p.s.i. Perform a  
leak test at normal gas pressure on all fittings after all  
connections have been made and the gas has been turned on. Soap  
test all connections of the gas system - bubbles indicate leaks.  
Gas Pressure  
GSW Water Heating Company recommends that the gas supply  
pressure as measured on the inlet side of the water heater  
control, be set at 7.0 inches water column for natural gas and 11.0  
inches water column for propane gas.  
Electrical Supply  
A three-wire cord and plug is provided with this water heater.  
The plug shall be connected into an electrically grounded, 120  
VAC, 60 Hz, 12 Amps, fused receptacle. The electrical supply  
-11-  
 
Important: in locations where a sump pump failure, flooding or  
exposure to water may be present, a ground fault receptacle is  
recommended.  
VI) Lighting and Operating Instructions  
WARNING  
READ BEFORE PROCEEDING  
If you do not understand and follow these  
instructions, a fire or explosion may result.  
This SuperflueÔ Water Heater is equipped with an electric  
combination thermostat / gas valve control and an ignition device  
that lights the burner. DO NOT ATTEMPT TO LIGHT  
THIS WATER HEATER MANUALLY! The control  
contains internal self-diagnostic features and an external LED  
monitor light (Figure 11).  
During operation a flashing LED indicates a burner or ignitor  
failure, putting the system into a safety lockout condition. This  
control uses three attempts at ignition before locking out. To  
reset a system in lockout, disconnect electrical power, wait ten  
seconds and re-energize. If the system fails to re-start, see  
trouble shooting section.  
A “constant on” LED indicates an unserviceable fault within the  
control, and cannot be reset. The complete control must be  
replaced.  
-12-  
 
Initial Start Up  
TURNING WATER HEATER OFF  
1. Turn thermostat to its lowest setting.  
1. With all gas valves closed and the power cord NOT plugged  
into an electrical outlet, make sure that the water heater is  
filled with water and that the cold water supply valve is open.  
2. Turn control switch to the “OFF” position.  
2. Open the manual shut off valve in the gas supply line and turn  
the water heater’s gas control switch to the “ON” position.  
Wait for five minutes. Smell around the water heater for any  
possible gas leak, Check close to the floor and around the  
burner door area as some gases, especially propane, are  
heavier than air.  
3. Turn gas supply valve “OFF”.  
4. If the blower is still running, wait for it to stop.  
5. Unplug electrical cord.  
Performance Checks  
IF YOU SMELL GAS:  
1. Burner Manifold Pressure - The burner operates at a manifold  
gas pressure of 3.5" W.C. for natural gas and 10.0" W.C. for  
propane gas. A _” N.P.T. port is provided on the gas valve  
control for connection to a gauge to measure the pressure  
(See Figure 11). The control valve has an internal pressure  
regulator. Do not confuse the manifold pressure with the  
supply inlet pressure. Return port plug upon completion of  
tests.  
Ø
Do not try to operate the water heater or any other  
appliance.  
Ø
Ø
Do not operate any electrical switch; do not use a telephone.  
Immediately call your gas supplier from a neighbor’s  
telephone. Follow the gas supplier’s instructions.  
2. Checking Input - Never exceed input shown on the rating  
plate. Ask your gas supplier for the heating value of the gas  
you are using. Check the input by ”clocking” the gas meter.  
Make sure no other appliances are operating when the test is  
being done. To ensure accuracy, clock enough gas so that the  
time is greater than 60 seconds. Use the following formula  
to check input. Check that your gas pressures are as  
previously stated.  
Ø
If you cannot contact your gas supplier, call the fire  
department.  
3. To start the water heater, set the thermostat to the mid  
point arrow on the dial (approximately 120°F, 50°C) and plug  
in the power cord. The system will start automatically.  
4. The gas valve will first do an initial diagnostic to check that  
it is working properly. Once proven, the control will energize  
the blower assembly and power through the pressure and  
high temperature safety switches.  
Input  
Gas Heating Value* x Cubic Feet/Meters clocked  
Seconds clocked  
=
(BTU/Hour)  
*Gas Heating Value in BTU/cubic feet or cubic meters  
1 cubic meter = 35.31 cubic feet  
5. With pressure and temperature safety switches proven,  
power is sent to the ignition system. The ignitor will glow until  
it reaches optimum temperature. Full glow takes  
approximately 15 seconds.  
3. Checking burner flame - Superflue Water Heaters may use  
either a sheet metal or cast iron burner. Access the burner  
by lifting off the outer gas door and sliding open the inner  
door located at the bottom of the water heater.  
6. With ignitor proven, the control will open the internal gas  
valve, allowing gas to flow to the burner. Main flame is  
established and envelops the flame sensor rod. This rod  
monitors flame stability. If the flame fails the system will  
shut down.  
·
for water heaters having a sheet metal burner and burning  
natural gas, a constant, steady, soft blue flame should be  
visible coming from the burner head  
7. The heater will continue to operate until the water  
temperature reaches the thermostat setting. At that time  
the burner will shut down, while the blower continues to  
operate for a brief post-purge sequence.  
·
for water heaters having a sheet metal burner and burning  
propane gas, the flame will be a constant, steady blue with a  
brighter blue being visible right at the burner head. The very  
ends of the flame may be tipped with yellow. This is more  
noticeable on higher input units.  
8. The water heater will remain off until the water temperature  
drops sufficiently to reactivate the system or the  
thermostat is set to a higher requirement.  
·
Noisy, hard blue flames, flames lifting from the burner,  
luminous or yellow stringy flames indicate an incorrect setup.  
Check that the unit is using the correct gas. This information  
-13-  
 
is on the rating plate and the label on the side of the gas  
valve control. Poor flames can also be caused by incorrect gas  
pressures or burner orifice size, inadequate or contaminated  
air, a restriction in the venting system, or dirt entering the  
For units with cast iron burners, the flame presentation  
should be the same as sheet metal burners. Adjustment is  
possible on cast iron burners by changing the air shutter  
position on the burner inlet. If the flame needs adjusting,  
loosen the two screws and move the shutter. See Figure 12.  
If it is too far open, the flame will lift or will be noisy; if it is  
closed too far, the flame will be luminous and yellow. Once  
proper flame is obtained, tighten the screws to secure the  
air shutter.  
gas supply. These conditions must be corrected to prevent a  
possible safety hazard.  
·
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 when it becomes totally  
consumed. Depending on water conditions, an anode can last from  
two to ten years. As with any water heater, it is good practice to  
check the anode annually to see if it needs replacing (Figure 1,  
Item No. 15).  
To inspect or change an anode:  
NOTE:  
Ø
There is no adjustment on sheet metal  
burners.  
turn off the water heater  
close the cold inlet supply valve  
ØAlways return the burner doors to their  
original position  
open a hot water tap supplied by the heater  
drain the water heater enough to empty the piping system  
using a 1 1/16" socket, remove anode and inspect or replace as  
required.  
refill system with water and restore water heater to  
operation  
WARNING  
Operating a water heater without an actively working anode rod  
will void the warranty.  
VII) GENERAL OPERATION AND  
MAINTENANCE  
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.  
Condensation  
Water vapor in the flue gases can condense on the cooler  
surfaces of the water heater, especially during the start of a  
cold tank, during heavy use, or if the water heater is undersized.  
Condensation can also be produced in the vent piping if the vent  
piping becomes chilled (e.g. going through unheated areas) or if  
the dilution air is very cold.  
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 chlorination and flushing of the water heater may be  
required. Contact you dealer or water supplier.  
Condensation may give the false impression that there is a tank  
leak as significant amounts can drip out of the bottom of the  
water heater. Once the water heater is operating at normal  
temperatures tank condensation should disappear. See venting  
section for dealing with condensation in the vent piping.  
Not Enough or No Hot Water  
Check that the water heater is operational  
Check that the thermostat is set high enough  
Cathodic Protection - Anode  
-14-  
 
Check that you have not just run out of hot water due to  
heavy demand. If this is a routine problem, it may indicate an  
under-sized water heater.  
technician. The replacement control must be an identical model  
to the control which has been removed.  
Water Temperature is Too Hot  
Have your gas company check input rate and water heater  
operation  
Check that thermostat setting is not too high  
The E.C.O. may have tripped open (LED indicator on  
constantly). See E.C.O. below.  
Water heaters used for dishwashers, space heating or  
laundry facilities generally require higher temperatures than  
domestic use. Install anti-scald tempering valves as  
instructed in the safety warnings  
Energy Cut-off Control (E.C.O.)  
This water heater is equipped with a control which has a built in  
E.C.O. (Energy Cut-off). The E.C.O. will shut the gas off, should  
the outlet water temperature exceed 200° F. If the E.C.O. has  
tripped, the entire gas control must be replaced. For gas control  
replacement, contact your local gas utility, or a qualified service  
If the problem persists, contact your dealer or gas supplier  
Hydrogen gas can be produced by water heaters in service but on  
standby for long periods of time (generally two weeks or more).  
See safety warnings in the front of the manual Hydrogen gas is  
extremely flammable. Use caution in opening faucets.  
Water Heater Makes Noise  
During start up or under heavy use, condensation can drip on  
the burner causing a sizzling noise as the water is  
evaporated. This is normal and will stop once temperatures  
rise.  
Tank Flushing  
Sediment, sand or scale can accumulate resulting in  
“rumbling” noises. Water heaters need to be flushed  
regularly to minimize buildup. Severe accumulations (more  
than 2" - 50 mm) can cause premature failure of the water  
heater and will void the warranty.  
Periodically (monthly) drain approximately 2 gallons (8 liters)  
from the tank through the drain valve. This will minimize sediment  
buildup on the tank bottom.  
Caution: WATER WILL BE HOT.  
Vent piping can vibrate if it is not supported properly. Ensure  
hangers and vibration isolators are properly installed.  
If scale removal is being considered, contact your dealer for  
proper procedures. DO NOT USE HYDROCHLORIC  
ACID (HCL) based cleaners. Thoroughly flush after any  
chemical cleaning.  
Discolored Water  
Water rich in iron or other minerals can produce red or brown  
staining. Heating water generally worsens this situation.  
Vent Maintenance  
Inspect the venting system periodically (minimum annually) to  
make certain that the venting passageways, vent terminal and  
blower assembly are free and unobstructed. Check that the vent  
connections are free and unobstructed, Check that the vent  
connections and vent joints are properly positioned and securely  
attached. In areas that have a high level of airborne particles  
(e.g. lint, sawdust, process smoke, etc.) Inspection and cleaning  
may need to be done more frequently.  
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. See  
also “Hot Water Odor”  
Relief Valve Check  
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.  
Inspect the relief valve annually to ensure proper operation. This  
involves opening the valve to check that it is flowing freely and  
that there are no blockages. Provide a bucket or drainage for the  
expelled water. Lift the lever and let it snap shut. The  
Extended Non Use  
-15-  
 
water should stop instantly. Warning: WATER WILL BE  
HOT and water flow can be forceful. 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 or to a thermostat that is  
operating at too high a temperature. In a closed water system, an  
expansion tank may be required Contact your local plumbing  
inspector. For a malfunctioning thermostat, contact your gas  
supplier.  
Burner Maintenance  
Annually inspect the burner and combustion chamber area to  
ensure that no debris have fallen on the burner and that no  
foreign material has found its way into the combustion chamber.  
Observe the flame for proper operation, Sheet metal burners  
have no adjustment, so contact your gas supplier if there is a  
problem.  
ALWAYS KEEP THE AREA AROUND THE WATER  
HEATER CLEAR OF COMBUSTIBLE MATERIALS.  
NEVER RESTRICT THE FLOW OF AIR TO THE  
WATER HEATER.  
-16-  
 
VIII) COMBINATION POTABLE WATER  
HEATING AND SPACE HEATING  
(COMBO HEATING)  
7. If local jurisdiction require a back-flow preventer in  
the cold water line, an expansion tank of adequate  
size must be installed.  
This section serves as a guide for the installation and use of  
“Combo” heating systems utilizing a domestic water heater which  
has been specifically approved for such use. It is written for  
those knowledgeable in the required trades and professionals  
involved in the design and installation of Combo Heating Systems.  
8. To reduce the scald hazard potential, a mixing valve  
must be installed.  
INSTALLATION  
The installation of the water heater must follow sections I to X  
in this manual. The heating mode may be one of the following  
options:  
It is the responsibility of the installer/ designer  
to follow all applicable codes to ensure the  
effectiveness and safety of the installation.  
A- A fan coil (air handler)  
Caution:  
READ BEFORE PROCEEDING  
B- A hydronic baseboard (finned tube) loop/ In floor heating  
The following requirements must be met for the installation of  
Combo Heating Systems:  
A- Fan Coil (see figure 13)  
The following is a list of requirements for the installation of the  
heating loop to the water heater.  
1. All components used for the distribution of water in the  
heating loop must be suitable for potable water. These  
include all piping, fittings, solder and fluxes, pumps for  
circulation of water, valves, etc.  
1) Install shut-off valves and unions so that the water  
heater can be isolated from the heating module  
should servicing of the water heater become  
necessary.  
2. The water heater must not be connected to a  
hydronic heating system that has been used  
previously.  
2) Install a drain valve at the lowest point of the heating  
loop so that water can be drained from the heating  
module without affecting the water heater.  
3. No boiler treatment chemicals of any kind shall be  
introduced into the system.  
3) If the air handler does not have a venting means at  
the highest point of the piping arrangement, install  
an air bleed at the highest point of the plumbing  
arrangement.  
4. The Combo System components must be selected  
and sized to meet and maintain the total calculated  
demands for both domestic service hot water and  
space heating requirement.  
The sizing and  
installation must be performed in accordance with  
good engineering practice such as ASHRAE  
Handbooks, HRAI, Hydronics Institute Manuals,  
CGA B149, NFPA 54, ANSI Z223.1, CSA F280,  
National/Provincial Building Codes, CSA C22.1,  
ANSI/NFPA 70, CSA B51 and/or codes having  
jurisdiction.  
B- Baseboard Radiator Heating (see figure 13)  
The following is a list of requirements for the installation of the  
heating loop to the water heater.  
1) Install shut-off valves and unions so that the water  
heater can be isolated from the heating module  
should servicing of the water heater become  
necessary.  
5. The air handler (fan coil) and/or the circulating pump  
in a baseboard hydronic loop will require a dedicated  
120V circuit. This must be provided and identified  
for this purpose.  
2) A drain valve must be installed at the lowest point of  
the heating loop so that water can be drained from  
the heating module without affecting the water  
heater.  
6. All piping between the water heater and the air  
handler or hydronic baseboard loop must be  
adequately insulated to reduce heat loss.  
-17-  
 
3) Install air bleed valves at the highest points to purge  
air from the system.  
-18-  
 
-19-  
 
-20-  
 

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