Installation Instructions and Use & Care Guide RESIDENTIAL GAS WATER HEATERS CANADIAN MANUAL FVIR GAS WATER HEATER (FLAMMABLE VAPOR IGNITION RESISTANT) FOR SPACE HEATING AND POTABLE WATER HEATING ONLY. NOT FOR USE IN MOBILE HOMES. This water heater complies with ANSI Z21.10.1-current edition / CSA 4.1-current edition regarding the accidental or unintended ignition of flammable vapors, such as those emitted by gasoline. For Your Safety AN ODORANT IS ADDED TO THE GAS USED BY THIS WATER HEATER.
TABLE OF CONTENTS Water Heater Safety .............................................................................................................................................................................. 1 Safe Installation, Use and Service ...................................................................................................................................................... 3 Safety Precautions ..........................................................................................
SAFE INSTALLATION, USE AND SERVICE Your safety and the safety of others is extremely important in the installation, use and servicing of this water heater. Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual.
Fire or Explosion Harzard Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. Avoid all ignition sources if you smell Natural or LP gas. Do not expose water heater control to excessive gas pressure. Use only gas shown on rating plate. Maintain required clearances to combustibles. Keep ignition sources away from faucets after extended period of non-use. Read instruction manual before installing, using or servicing water heater.
TYPICAL INSTALLATION GET TO KNOW YOUR WATER HEATER - GAS MODELS A B C D E F G H I Vent Pipe Draft Hood Anode (Not Shown) Hot Water Outlet Insulation Gas Supply Piping Manual Gas Shut-off Valve Ground Joint Union Drip Leg (Sediment Trap) J K L M N O P Q R Inner Door Outer Door Union Inlet Water Shut-off Valve Cold Water Inlet Inlet Dip Tube Temperature-Pressure Relief Valve Rating Plate Flue Baffle S T U V W X Y Gas Control Valve/Thermostat Drain Valve Manifold/Burner Assembly Flue Metal Drain Pan Piezo
INSTALLING YOUR GAS WATER HEATER Important Information About This Water Heater Unpacking the Water Heater This gas water heater was manufactured to voluntary safety standards to reduce the likelihood of a flammable vapor ignition incident. New technology used in meeting these standards makes this product more sensitive to installation errors or improper installation environments.
Location Requirements If flammable liquids or vapors 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. WARNING Carbon Monoxide Poisoning Hazard WARNING Do not install in a mobile home. Doing so can result in carbon monoxide poisoning and death.
• Devices that will turn off the gas supply to a gas water heater while at the same time shutting off its water supply. EXHAUST FAN IMPORTANT: The water heater should be located in an area where leakage of the tank or connections will not result in damage to the area adjacent to the water heater or to lower floors of the structure. Due to the normal corrosive action of water, the tank will eventually leak after an extended period of time.
GAS SUPPLY WARNING MANUAL GAS SHUT-OFF VALVE GROUND JOINT UNION CHECK WITH LOCAL UTILITY FOR MINIMUM HEIGHT Explosion Hazard 3 in. (7.62 cm) MINIMUM 12 in. (300mm) MAXIMUM AIR GAP • Use a new CSA approved gas supply line. • Install a shut-off valve. DRIP LEG • Do not connect a natural gas water heater to an L.P. gas supply. FIGURE 3. Gas Pressure • Do not connect an L.P. gas water heater to a natural gas supply.
LP Gas Only Liquefied petroleum gas is over 50% heavier than air and in the occurrence of a leak in the system, the gas will settle at floor level. Basements, crawl spaces, closets and areas below ground level will serve as pockets for the accumulation of gas. Before lighting an L.P. gas water heater, smell all around the appliance at floor level. If you smell gas, follow the instructions as given in the warning on the front page. WARNING Explosion Hazard When your L.P.
COMBUSTION AIR & VENTILATION TABLE 1 WARNING Carbon Monoxide Warning BTU/HR (kW) Input Follow all the local and provincial codes or, in the absence of local and provincial codes, the “Natural Gas and Propane Installation Code,” CSA B149.1-current edition to properly install vent system. 30,000 (8.79) 45,000 (13.18) 60,000 (17.58) 75,000 (21.97) 90,000 (26.37) 105,000 (30.76) 120,000 (35.15) 135,000 (39.55) Failure to do so can result in death, explosion, or carbon monoxide poisoning.
However, it must never be lower than the relief opening of the draft hood. See Figure 4. CONFINED SPACE 12 in. (30.5 cm) MINIMUM ABOVE GRADE & SNOW LEVELS AS CLOSE TO CEILING AS POSSIBLE AND ABOVE DRAFT HOOD. GRADE COMBINATION COMBUSTION/ VENTILATION AIR DUCT CLOSET OR OTHER CONFINED SPACE PERMANENT OPENINGS TO ADDITIONAL ROOMS WITHIN THE BUILDING WITHIN 12 in. (30.5 cm) ABOVE BURNER LEVEL WITHIN 24 in.
CSA B149.1-current edition (Natural Gas and Propane Installation Code) and all local/provincial codes. location. A single wall metal vent connector cannot pass through any interior wall. When installing a vent connector, please note the following (See Figures 16-18): The vent pipe installation must not be obstructed so as to prevent the removal of exhaust gases to the outside atmosphere. • IMPORTANT: • • • • The use of vent dampers is not recommended by the manufacturer of this water heater.
Do not terminate the vent connector in a chimney that has not been certified for this purpose. Some local codes may prohibit the termination of vent connectors in a masonry chimney. installations and may or may not be typical for your specific application. Consult the “Natural Gas and Propane Installation Code,” CAN/CSA B149.1-current edition and the guidelines set forth by prevailing local codes.
WATER SYSTEM PIPING Piping Installation IN A CLOSED SYSTEM, USE A THERMAL EXPANSION TANK Piping, fittings, and valves should be installed according to the installation drawing (Figure 11). If the indoor installation area is subject to freezing temperatures, the water piping must be protected by insulation. MAIN WATER SUPPLY PRESSURE REDUCING VALVE WITH BYPASS The water supply pressure should not exceed 80 psi (551.58 kPa).
• • • • It is recommend that only full flow ball or gate valves are used in water piping installations. The use of valves that may cause excessive restriction to water flow is not recommended. Use only 95/5 tin-antimony or other equivalent solder. Any lead based solder must not be used. Piping that has been treated with chromates, boiler seal, or other chemicals must not be used. Chemicals that may contaminate the potable water supply must not be added to the piping system.
4. 5. 6. 7. 8. to the insulation to ensure that it is fully seated on the T&P Relief Valve. Once seated, secure the insulation with duct tape, electrical tape, or equivalent. IMPORTANT: The insulation or tape should not block or cover the T&P relief valve drain opening. Also, the insulation or tape should not block or hinder access to the manual relief lever (Figure 13B). Ensure that a discharge pipe is installed into the T&P valve discharge opening per the instructions in this manual.
IMPORTANT INFORMATION ABOUT THIS WATER HEATER This gas water heater was manufactured to voluntary safety standards to reduce the likelihood of a flammable vapor ignition incident. The new technology used in meeting these standards makes this product more sensitive to installation errors. Please review the following checklist and make any required installation upgrades or changes.
OPERATING YOUR WATER HEATER Lighting Instructions WARNING Read and understand these directions thoroughly before attempting to light or re-light the pilot. Make sure the view port is not missing or damaged. (See Figure 21.) Make sure the tank is completely filled with water before lighting the pilot. Check the rating plate near the gas control valve/ thermostat for the correct type of gas. Do not use this water heater with any gas other than the one listed on the rating plate.
FOR YOUR SAFETY READ BEFORE LIGHTING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. FLAMMABLE BEFORE LIGHTING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES A. This appliance has a pilot which is lit by a piezo- C. Use only your hand to push in or turn the gas control knob. Never use tools. If the knob will not push in or electric spark gas ignition system.
Checking the Draft Water Temperature Regulation WARNING Water temperature over 125°F (52°C) can cause servere burns instantly resulting in severe injury or death. Burn Hazard Children, the elderly, and the physically or mentally disabled are at highest risk for scald injury. Do not touch vent. Doing so can result in burns. Feel water before bathing or showering.
Water Temperature °F (°C) Time for 1st Degree Burn (Less Severe Burns) 110 (43) 116 (47) 116 (47) 122 (50) 131 (55) 140 (60) 149 (65) 154 (68) (normal shower temp.) (pain threshold) 35 minutes 1 minute 5 seconds 2 seconds 1 second Instantaneous Water Temperature Adjustment Time for Permanent Burns 2nd & 3rd Degree (Most Severe Burns) The water temperature setting can be adjusted from 55°F (12.7°C) to 155°F (68.3°C). Turn the Gas Control/ Temperature Knob to the desired setting/temperature.
Excessive condensation can cause pilot outage due to water running down the flue tube onto the main burner and putting out the pilot. 4. The ignition of flammable vapors. A thermopile is used to determine if a pilot flame is present, and will shut off the gas supply to the main burner and the pilot if the flame is absent.
The following are typical (but not all) signs of a depleted anode rod: • The majority of the rod’s diameter is less than 3/8” (9.5 mm). • Significant sections of the support wire (approx. 1/3 or more of the anode rod’s length) are visible. If the anode rod show signs of either or both it should be EXPOSED replaced. NOTE: Whether SUPPORT re-installing or replacing the WIRE anode rod, check for any leaks and immediately correct if found. In replacing the anode: PITTED ANODE 1.
properly. To prevent water damage, the valve must be properly connected to a discharge line which terminates at an adequate drain. Standing clear of the outlet (discharged water may be hot), slowly lift and release the lever handle on the temperature and pressure relief valve to allow the valve to operate freely and return to its closed position. See Figure 19.
Replacing the Pilot/ Thermopile Assembly 1. 7. Route the new pilot tube, igniter wire and thermopile wire through the opening in the manifold door. See Figure 23. Remove the manifold door assembly as described in “Removing the Manifold/Burner Assembly” section. 8. Using the pilot screw removed earlier, attach the new pilot/thermopile assembly and the pilot shield. Reattach the burner to the manifold using the screws removed earlier.
External Inspection & Cleaning of the Base-Ring Filter 1. Replacing the Manifold/Burner Assembly WARNING At least annually, check the base-ring filter (Figure 26) for any dust or debris that may have accumulated on the filter screen. NOTE: If the water heater is located in an area that is subjected to lint and dirt, it may be necessary to check the base-ring filter more frequently. 2.
Removing and Replacing the Gas Control Valve/Thermostat 7. Connect the white and red wires to the gas control valve/thermostat as shown in Figure 21. Also, ensure that the red thermal switch wires are connected to the thermal switch on the manifold door.. IMPORTANT: This water heater has a resettable thermal switch installed. Do not attempt to disable or modify this feature in any way. Use only factory authorized replacement parts. Removing the Gas Control Valve/Thermostat: 1.
FVIR System Operational Checklist 1. 2. 3. 4. 5. 6. 7. Manifold gasket properly sealed. Viewport not damaged or cracked. Flame-arrestor free of debris and undamaged. Manifold component block properly installed. No leaks at pilot and manifold connection. Manifold door screws securely tightened. Depress the button on the thermal switch TROUBLESHOOTING CHART PROBLEM BURNER WILL NOT IGNITE POSSIBLE CAUSE(S) 1. 2. 3. 4. 5.
PROBLEM SLOW HOT WATER RECOVERY POSSIBLE CAUSE(S) 1. Insufficient combustion air 2. Water heater flue or vent system blocked 3. Low gas pressure 4. Improper calibration 5. Base-Ring Filter blocked with lint/ dust 6. FVIR Flame Arrestor blocked with lint/dust. CORRECTIVE ACTION 1. Provide ventilation to water heater. Check flue way, flue baffle, and burner 2. Clean flue, locate source and correct 3. Check with gas utility company 4. Replace thermostat 5.
PILOT LIGHT TROUBLESHOOTING FLOWCHART Section A: Pilot light will not light (new installation). Section C: Pilot light will not remain lit. Is the manual gas shut-off valve, located in the supply line to the water heater, in the on position? YES Check for insufficient combustion air. Complete this section after completing Section B.
STATUS LIGHT AND DIAGNOSTIC CODE TROUBLESHOOTING CHART LED STATUS 0 FLASHES (LED NOT LIT) PROBLEM CORRECTIVE ACTION Pilot light is not lit or Thermopile has not yet reached normal operating temperature. Turn Gas Control Valve/Thermostat knob to OFF. Wait 10 minutes, then attempt to relight Pilot by following the lighting instructions on the water heater’s label. Until the Thermopile reaches its normal operating temperature, the Status Light will not blink, even if the Pilot is lit.
STATUS LIGHT AND DIAGNOSTIC CODE TROUBLESHOOTING CHART (Continued) LED STATUS PROBLEM CORRECTIVE ACTION 4 FLASHES The Gas Control Valve’s temperature sensor has detected that the water temperature was too high. Once this condition occurs, the Main Burner and the Pilot Light will be shut off. Since the Pilot light will be off, should this condition occur, this Flash Code will only be displayed immediately after the Pilot has been relit. Turn Gas Control Valve/ Thermostat knob to OFF.
REPAIR PARTS ILLUSTRATION 1 When ordering repair parts, always give the following information: 1. 2. 3. 4. 3 Model, serial, and product number Type of gas Item number Parts description 2 4 5 6 8 Repair Parts List Item No.
Listed Parts Kits and Illustrations Item 11A: Pilot / Thermopile Assembly kit, which contains the pilot / pilot tube assembly, thermopile, and igniter electrode. (Natural Gas) Item 11B: Pilot / Thermopile Assembly kit, which contains the pilot / pilot tube assembly, thermopile, and igniter electrode. (L.P. Gas) Item 12A: Burner (Natural Gas/Low Nox) Item 12B: Burner (L.P.
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LIMITED WARRANTY When referencing the water heater for service or warranty, please refer to the rating plate af xed to the unit. The Model Number contains the warranty period. Example: JW850SDEB Inner Tank Warranty Years Component Part Warranty Years JW 8 6 The Serial Number contains the manufacture date information for the unit as follows: Example: 1005 F001234 Manufactured in week 5 Manufactured in 2010 RESIDENTIAL STORAGE TANK TYPE WATER HEATER FOR INSTALLATION IN A SINGLE FAMILY DWELLING A.
Canadian Electrical Code; or c. The water heater is not installed, operated, and maintained in accordance with the Manufacturer’s instructions, including if the water heater has any additional aftermarket equipment introduced into the sealed system not approved by the Manufacturer; or d. The water heater or any of its component parts are damaged or fails from operation with an empty or partially empty tank (such as, but not limited to elements burned out in a dry tank); or e.
John Wood Water Heaters 599 Hill Street West Fergus, ON Canada N1M 2X1 Should you have any questions, please Visit us online at www.johnwoodwaterheaters.com, or E-mail us at techsupport@gsw-wh.