GSW WATER HEATING
599 Hill Street West
Fergus, ON, Canada N1M 2X1
STORAGE BOOSTER TANKS
INSTALLATION AND OPERATING INSTRUCTIONS
Read and understand these instructions thoroughly before starting
TABLE OF CONTENTS
I)
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
II) Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
III) Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
IV) Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
V) Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
PLEASE RETAIN THESE INSTRUCTIONS IN A
SAFE LOCATION FOR FUTURE REFERENCE
WARNING:
Improper installation, adjustment, alter-
ation, service, or maintenance can cause
injury or property damage. Refer to this
manual. For assistance or additional infor-
mation, consult a qualified installer, serv-
ice agency, or the electric utility.
FOR YOUR SAFETY
• Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
• Installation and service must be per-
formed by a qualified installer, service
agency or the electric utility.
WARNING:
If the information in these instructions is
not followed exactly, a fire or explosion
may result causing property damage, per-
sonal injury or death.
GSW Water Heating is a division of GSW Water Products Inc.
PART NO. 71772 C (05-02)
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tenance and service must be provided. Water lines and the
storage tank should be protected from freezing tempera-
tures. Do not install the storage tank in outdoor unprotected
areas. It is desirable to have a floor drain nearby to permit
easy draining if necessary.
IMPORTANT
Do not apply heat directly to tank fittings when making
sweat connections. They contain non-metallic material.
2. Install circulation loop as shown using 19mm (¾ in.)
copper pipe.
3. Install the cold water supply piping into a tee between
the circulator discharge and the boiler coil inlet.
4. Connect the boiler supply line to the combination return
and drain valve.
5. Connect hot water supply to top tank fitting.
6. Install 19mm (¾ in.), 150 psi Temperature and Pressure
Relief Valve into the tank as shown.
7. A check valve may be installed between the cold water
tee connection and the circulator. This will force the cold
water through the coil first.
WARNING
The water heating source piping and components con-
nected to the tank must be suitable for potable water use.
TOXIC chemicals such as used for boiler treatment must
not be introduced into the tank.
Circulator Pump
A circulator pump is not supplied. Use only a bronze body
model rated for 110/120 volts, 60Hz. Install in accordance
with the pump manufacturer’s instructions using standard
plumbing practices.
NOTE: The check valve can often be noisy and cause
reduced supply pressures. For multiple storage tank sys-
Plumbing Connections
CHECK VALVE
PRESSURE
REGULATOR
(OPTIONAL)
EXPANSION TANK (OPTIONAL)
The main parts and features of your storage booster tank
are identified in Figure 1. Install plumbing according to
Figure 2 for single storage tank and according to Figure 3
for multiple storage tank systems.
CIRCULATOR
PUMP
T&P VALVE
HOT
1. Ensure the storage tank is level before starting installa-
tion.
COLD
T&P VALVE
(FOR SOME
MODELS)
SUPPLY (TO BOILER
TANKLESS COIL)
JUNCTION BOX
T&P VALVE (SOME
MODELS WILL HAVE
A SIDE MOUNT FOR
THIS VALVE)
HOT
STORAGE
BOOSTER
TANK
HOT
WATER
OUTLET
TANKLESS
COIL BOILER
COMBINATION RETURN
& DRAIN VALVE
Figure 2: Single Storage Booster Plumbing Diagram
ANODE
CHECK VALVE
PRESSURE
REGULATOR
(OPTIONAL)
EXPANSION TANK (OPTIONAL)
CIRCULATOR
PUMP
T&P VALVE
HOT
T&P VALVE
HOT
COLD
CHECK
VALVE
T&P VALVE
(FOR SOME
MODELS)
ACCESS
DOORS
THERMOSTAT
CONTROL
HOT
STORAGE
BOOSTER
TANK
STORAGE
BOOSTER
TANK
TANKLESS
COIL BOILER
COMBINATION
RETURN &
DRAIN VALVE
THERMOSTAT
RETAINER
COMBINATION RETURN
& DRAIN VALVE
Figure 3: Multiple Storage Booster Plumbing Diagram
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Figure 1: Main Parts and Features
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tem, check valves must be installed to prevent the circulator
from pumping hot water into another tank and overheating
it.
8. The use of a pressure regulator is optional, but recom-
mended when the cold supply pressure is over 80 psi.
nection at the service panel to the ground screw at the
junction box.
4. The thermostat is rated for a maximum inductive current
of 7 FLA at 120 VAC. Do not exceed this rating for the
circuit.
Reducing the inlet pressure to 45-60 psi will reduce 5. Do not install or connect electrical heating elements to
probability of relief valve discharge by thermal expan-
sion.
this tank.
9. The water utility supply meter may contain a check
valve, back-flow preventer or water pressure reducing
valve. This will create a closed water system. During the
heating cycle, the water expands creating a pressure
build-up in the water system. A Temperature and
Pressure (T&P) Relief Valve must be installed (150 psi
maximum pressure). See preceding section. If the T&P
valve discharges periodically, this may be due to ther-
mal expansion in a closed system. To prevent this con-
dition and to reduce the possible build up of lime on the
Temperature and Pressure Relief Valve seat, either one
of the following installations is required;
Filling
NOTE: When filling, avoid water leakage. Do not allow the
insulation of the tank to get wet as water can cause electri-
cal malfunction or reduce the effectiveness of the insulation.
1. To insure complete filling of the tank, allow air to exit by
opening a hot water faucet that is served by the tank
and is some distance away from the heater.
2. Ensure the storage tank drain valve is closed.
3. Open the cold water supply valve and fill the tank and
piping system with water. When an uninterrupted
stream of water, without apparent air bubbles, flows
from the open hot water faucet, the system is full.
4. Close the open hot water faucet. Check the system for
leaks, repair as necessary and retest.
5. Connect a hose to the drain valve and route to a suit-
able drain. Open the drain valve and let water run to
flush out any foreign matter that may have entered the
system. Once flushed, close the drain valve and dis-
connect hose.
i) Install a 125 psi pressure relief valve in the cold water
supply line. Make sure that the discharge of this valve is
protected from freezing and directed to an open drain.
ii) Install an expansion tank on the cold water supply
line.
10. A vacuum relief valve may be installed to provide vent-
ing of a closed system. Check local code requirements.
Electrical Wiring
Temperature Regulation
120 VOLT SUPPLY
CIRCULATOR
DANGER
PUMP
L1
L2
JUNCTION BOX
(AT CASING TOP)
WIRE CONNECTORS
BOOSTER TANK
MUST BE
GROUNDED TO
THE ELECTRICAL
SUPPLY SERVICE.
BLACK
BLACK
THERMOSTAT
In order to reduce the risk of scald injury, the thermostat is
factory set to 49°C (120°F). The thermostat operates auto-
matically and can be adjusted to provide higher or lower
water temperature as needed. A mixing valve in connection
with a higher temperature setting should be used to reduce
risk of scald injury.
IF WIRE HAS TO BE REPLACED IN THE FIELD,
USE ONLY TYPE TEW 105°C WIRE.
Figure 4: Wiring Diagram
Electrical wiring must be in accordance with local codes; or
in the absence of local codes with the National Electrical
code ANSI/NFPA 70 or The Canadian Electrical Code, as
applicable.
1. Supply 110/120 volt, 60Hz power, to the junction box
located at the top of the tank.
2. Connect the circulator pump in series with the thermo-
stat as shown in Figure 4.
3. A ground wire must be supplied from the ground con-
CAUTION
Increasing the thermostat setting above the pre-set tem-
perature may cause severe burns and consume exces-
sive energy. Hotter water increases the risk of scald injury.
IMPORTANT
RISK OF SCALDING. Hot water will cause third degree
burns in 6 seconds at 60°C (140°F), in 30 seconds at 54°
(130°F).
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immediately. If it fails to reset completely and continues to
release water, the valve is not functioning properly and must
be replaced immediately. Close the cold water supply valve,
drain the tank as directed in the “Draining and Flushing”
section, and replace the T&P valve with a new one. Failure
to install and maintain an approved T&P valve will release
the manufacturer from any claim that might result from
excessive temperature or pressure. In systems where the
relief valve discharges periodically, this may be due to ther-
mal expansion or to a thermostat that is operating at too
high a temperature. If you suspect a malfunctioning thermo-
stat, contact a qualified service technician for repairs.
IV) OPERATION
1. Follow boiler or heat source installation and operating
instructions.
2. Fill the tank (see “FILLING” section).
3. The boiler or water heating source should be set to pro-
vide at least 11°C (20°F) higher water temperature than
the temperature setting of the storage tank
4. Turn power on, check for proper operation of boiler and
storage tank.
Temperature Adjustment
The setting of 49°C (120°F) has been proven to be satis-
factory from the standpoint of operational costs and safety.
We recommend the thermostats remain set at 49°C
(120°F).
Draining and Flushing
Some service work to be performed on the tank requires the
tank to be drained. It is also recommended that the tank be
drained and flushed every 6 months to remove any sedi-
ment and lime which may build up in the bottom of the tank
during operation. Such buildup can result in noisy operation.
To drain the tank:
If water temperature adjustment is required:
1. Turn "OFF" the electrical supply to the tank.
2. Remove lower access door.
3. Turn back insulation.
1. Turn "OFF" the electrical supply to the tank.
2. Close the cold water supply valve.
3. Open a nearby hot water faucet served by the system.
4. Connect a hose to the drain valve and route it to an ade-
quate drain.
CAUTION! The water being drained can be extremely
hot! The drain hose should be rated for at least 93°C
(200°F). If the drain hose does not have this rating, open the
cold water supply valve and a nearby hot water faucet
served by the system until the water flow is no longer hot.
Close the cold water supply valve and resume.
5. Open the drain valve and allow all the water to drain
from the tank.
6. Open the cold water supply valve and flush the tank as
needed to remove sediment and any other foreign mat-
ter that may have entered the system. Close the cold
water supply valve when clean water flows.
4. Adjust thermostat to water temperature desired.
5. Replace insulation and access door.
6. Turn "ON" the electrical supply to the tank.
V) MAINTENANCE
T&P Valve Check
CAUTION
The out-flowing water is hot. Avoid splashing the water on
yourself or on the surroundings where it may cause dam-
age.
Do not attempt to operate this storage tank with the cold
water inlet valve closed. The Temperature and Pressure
Relief Valve must be manually operated at least once a
year. This involves opening the valve to check that it is flow-
ing freely and that there are no blockages. WARNING!
WATER MAY BE HOT and water flow can be forceful.
Caution should be taken to ensure that:
1. No one is in front of or around the outlet of the T&P
valve discharge line.
2. The water manually discharged will not cause any bod-
ily injury or property damage. The water may be
extremely hot.
7. Perform any other servicing as required.
8. Close the drain valve, disconnect hose and refill the
tank (see “FILLING” section).
9. Turn "ON" the electrical supply to the tank.
Cathodic Protection
Your storage booster tank has been equipped with one or
more anodes that protect the tank from corrosion. Over
time, as the anode works, it slowly dissolves and must be
replaced. If the anode(s) is less than 10mm (3/8 in.) in diam-
eter, or has any of the inner steel core exposed, it must be
replaced. Depending on water conditions, an anode can last
from one to ten years. Many localities treat their water and
this can have a significant effect on the life of your heater.
Water conditioning, such as over-softening, can accelerate
the rate at which the anode(s) is consumed. Rapid depletion
can leave a heater unprotected causing a premature failure.
It is good practice to check the anode(s) annually to see if it
needs replacing. Operating a storage tank without an
actively working anode(s) will void the warranty. Failure to
maintain the anode may result in premature failure of the
storage tank due to corrosion and leaks.
While standing clear of the outlet (discharge water may be
hot), lift the lever and let it snap shut. The water should stop
Temperature and Pressure
Relief Valve
Manual Relief Valve
Discharge line to drain
Figure 5: T&P Valve Test
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Anode Maintenance
1. Turn "OFF" the electrical supply to the tank.
2. Close the cold water supply valve.
3. Open a nearby hot water faucet served by the system
to depressurize the system.
4. Connect a hose to the drain valve and drain 22 litres (6
gal.) as directed in the “Draining and Flushing” section.
NOTE: The anode(s) has been factory installed using a
power tool. It may be necessary for a second person to sta-
bilize the tank. A few sharp blows on the handle of the sock-
et wrench should loosen the anode nut. If an impact wrench
(power drive) is available, this is an easy way to remove an
anode.
6. Using a 1 1/16" socket, remove anode(s) and inspect it.
The surface may be rough, full of pits and crevices, but
this is normal. If it is less than approximately 10mm (3/8
in.) in diameter, or the inner steel core is exposed, the
anode(s) should be replaced.
®
7. Apply Teflon tape or sealing compounds approved for
use with potable water, to the threads of the anode(s)
and install into the tank top.
8. Open the cold water supply valve and open a nearby
hot water faucet to purge air from the tank as directed
in the “Filling” section.
9. Check for leaks, repair as required, and re-test.
10. Turn "ON" the electrical supply to the tank.
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~ Certificate of Warranty ~
Warranty Code: P R S T U V W
Y
See Rating Label Serial Number prefix for
Warranty Code. Reduced warranty period
applies to Newfoundland.
Standard Warranty Years: 3 5 6 7 8 9 10 12
Reduced Warranty Years: 2 3 3 5 5 5
5
7
For its GSW and John Wood water heaters and storage boosters ("Unit"), GSW Water Heating ("GSW") warrants that, upon
receipt of a properly verified Warranty claim within the Warranty Period, it will, at its election, repair or replace: units which leak or parts which are defective
in material or workmanship, subject to the terms and conditions set forth in this certificate. GSW will not assume any expense or liability for unauthorized
returns, nor repairs made by a person who has not been authorized by GSW or one of its authorized dealers. GSW Units/parts must be replaced with GSW or
John Wood products to be eligible for Warranty. This Warranty is available to the original owner of a Unit installed within the boundaries of continental United
States, of Canada, or their territories. Consumers must retain point-of-sale proof of purchase to validate warranty entitlement. This Warranty does not
cover components not manufactured by GSW, such as oil burners, which carry the warranty given by the manufacturer thereof, copy of which warranty GSW
will make available, to the extent supplied by the manufacturer, without recourse to GSW.
THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF. THIS EXPRESS
WARRANTY IS, WHERE PERMITTED BY LAW, IN LIEU OF AND EXCLUDES AND REPLACES ALL OTHER CONDITIONS,
WARRANTIES, GUARANTEES, REPRESENTATIONS, OBLIGATIONS OR LIABILITIES OF GSW OF ANY NATURE OR KIND,
EXPRESS OR IMPLIED, HOWEVER ARISING (WHETHER BY CONTRACT, CONDUCT, STATEMENT, STATUTE, NEGLI-
GENCE, PRINCIPLES OF MANUFACTURER'S LIABILITY, OPERATION OF LAW OR OTHERWISE) WITH RESPECT TO THE
UNIT OR ITS FITNESS FOR A PARTICULAR PURPOSE, MERCHANTABILITY, INSTALLATION, OPERATION, REPAIR OR
REPLACEMENT. GSW EXPRESSLY DISCLAIMS ANY AND ALL IMPLIED WARRANTIES. IN NO EVENT WILL GSW'S LIA-
BILITIES EXCEED THE COST OF THE DEFECTIVE PART(S) OR UNIT. GSW WILL NOT PAY FOR ANY TRANSPORTATION,
LABOUR, INSTALLATION, OR OTHER INCIDENTAL COSTS ASSOCIATED WITH THE REPAIR OR REPLACEMENT OF A
DEFECTIVE PART OR UNIT.
This warranty and GSW's obligations shall be construed and determined in accordance with the laws of both the Province of Ontario, and of Canada in force
therein. This Warranty does not affect specific legal rights of a consumer under applicable law, except to the extent that such rights may be waived or replaced,
and the provisions hereof are deemed to be amended to the extent necessary. The unenforceability of any provision, in whole or in part, of this Certificate shall
not affect the remaining provisions. Any and all repair and/or replacement of part(s) or Unit are the sole and exclusive remedy available against GSW.
LIABILITY OF GSW COVERED BY THIS WARRANTY IS CONDITIONAL UPON THE FOLLOWING:
1. The Unit shall be installed in accordance with all manufacturers' instruc- 7.
tions, all applicable equipment and building codes, ordinances and regu-
lations (hereinafter referred to as the "standards").
A properly documented claim shall be received by GSW or one of its
authorized dealers, or point of purchase, within the following Warranty
Period, except as provided otherwise below*:
2. The Unit must not be installed where water damage can result from a
leak, while provision(s) shall be made for directing any water escaping
from the Unit, to a properly operating drainpipe. As all units of this type
may eventually leak, you must protect against any potential water dam-
age. GSW accepts no responsibility for such damage, nor any incidental
or consequential loss, nor damage(s) related thereto, suffered by the
owner of the Unit nor by any third party.
3. The Unit shall not be installed where it will be exposed to adverse or
unusual environmental or corrosive conditions. No warranty extends, for
example, and without limitation of the foregoing, to Units exposed to:
salts; chemicals; exhausts; pollutants or contaminants. Further, no war-
ranty extends to Units affected by fire, freezing or flood, "Acts of God",
or any other contingency beyond the control of GSW.
a) for any defective part, within one (1) year; or
b) for any Unit that develops leaks in the inner tank due to rust, corrosion
or other chemical reactions caused by the potable domestic water sup-
plied to your home, within the period of time shown in table at the top of
this page.
* Residential units installed and used in a commercial application carry a
warranty period of one (1) year from date of installation; and,
Any repair or replacement of any part, tank, or Unit under this Warranty
will not extend the Warranty Period beyond that calculated from the date
of first installation of the original Unit. The date of first installation will
be deemed to be the later of the date indicated by the Unit's serial num-
ber, or if supplied with the Warranty claim, the sales receipt, or installer's
receipt.
4. The Unit shall be equipped with a properly operating temperature and 8. A claim under this Warranty must include the model and serial number of
pressure relief valve as specified by GSW and applicable standards. The
Unit shall be operated at temperatures not exceeding the maximum set-
ting of the thermostat and/or high limit control provided by GSW, and at
water pressures not exceeding the pressure reading stated on the Unit.
5. The Unit must be carefully inspected, maintained, and operated in accor-
dance with the manufacturer's instructions. No warranty extends, for
example, and without limitation of the foregoing, to any Unit operated:
without the tank being completely filled with water; without an operating
anode; with levels of sediment or lime precipitate which cause failure; in
connection to any attachment(s), energy saving device(s), or other means
the Unit, proof of date on which the Unit was first installed, and the iden-
tity of the defective part(s) for which a claim is being made and be sub-
mitted within 15 days following discovery of the defect(s), by personal
delivery to a GSW authorized dealer, point of purchase, or GSW itself at:
GSW Water Heating
GSW Water Heating is a division of GSW Water Products Inc.
599 Hill Street West
Fergus, ON Canada N1M 2X1
Should you have questions, please call our Technical Support Line at 1-
888-479-8324.
of heating, except as approved by GSW for the Unit; other than with 9. If requested by GSW, information relating to the purchase, transportation,
potable water without any additives such as salts, chlorine or chemicals,
except those added for the sole purpose of rendering the water fit for
domestic use.
operation and installation of the Unit must be supplied. The defective
part(s) or Unit, with all components properly and securely packed, shall
be returned transportation pre-paid, to the address designated by GSW in
the written request. All claims are subject to validation by GSW.
6. All repairs must be made by a competent and qualified person who is cer-
tified, by GSW or one of its authorized dealers, to work on the Unit, using
factory approved replacement parts, and the Unit shall not be otherwise
modified, altered or improperly repaired.
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