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
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•
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
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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.
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3) Install air bleed valves at the highest points to purge
air from the system.
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