Girard Products GSWH-1 Service Manual
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Girard Products GSWH-1 Service Manual

Lp gas tankless water heater for recreation vehicles
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Service Manual
Model: GSWH-1
Model: GSWH-1M
LP Gas
Tankless
Water Heater
For Recreation Vehicles
This manual is intended solely for use by trained personnel
who perform service or repairs on the Model GSWH-1 and
GSWH-1M Water Heater on behalf of a Girard Products LLC
Authorized Service Center.
For Recreation
Model: GSWH-1 Patent Pending
Model: GSWH-1M Patent Pending
CSA Approved
Girard Products LLC, 1361 Calle Avanazado, San Clemente CA 92673 U.S.A
Service Manual Part No. 1GWHM9405 - 10/1/2014

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Summary of Contents for Girard Products GSWH-1

  • Page 1 Water Heater For Recreation Vehicles This manual is intended solely for use by trained personnel who perform service or repairs on the Model GSWH-1 and GSWH-1M Water Heater on behalf of a Girard Products LLC Authorized Service Center. For Recreation...

  • Page 2: Table Of Contents

    Normal Operation GSWH-1M ................8-9 Recommended Tools and Equipment ..............10 Removing Controls Housing .................. 11 Schematics and Diagrams a. Ladder Diagram GSWH-1 & GSWH-1M ............12 b. Wiring Diagrams ...................13 10. Circuit Board Operation ..................14 11. Troubleshooting Guide/ Exploded Views ............15-16 12.

  • Page 3: Introduction

    INTRODUCTION Must Read!) The original Girard Water Heater was Model Number 1GWH/1GWHAF. AF indicates (Winter Use Device). The front portion of this manual will concentrate on the models listed above. In August 2012 Girard redesigned and replaced the original product and assigned the Model Number GSWH-1M, referred to as the M-Series.

  • Page 4: Product Identification Gswh-1

    Door Part Number: 1GWHD, 1GWHDA6, 1GWHDAS10 Serial Number Location: Rating Label affixed on the inside right of the Controls Housing. Figure 1 Specifications The main performance specifications of the Model GSWH-1 are: BTU/HR 27,000 – 34,000 Fuel Propane (LP Gas) Inlet Pressure 10.5”...

  • Page 5: Product Identification Gswh-1M

    PRODUCT IDENTIFICATION - GSWH-1M Water Heater Part Number: 1GWH-1M Door Part Number: 1GWHD, 1GWHDA6, 1GWHDAS10 Serial Number Location: Rating Label affixed to Blower Assembly Housing Figure 1a Specifications The main performance specifications of the Model GSWH-1M are: BTU/HR 18,000 – 36,000 Fuel Propane (LP Gas) Inlet Pressure...

  • Page 6: Description And Features

    DESCRIPTION AND FEATURES The Girard Products GSWH-1 LP and the GSWH-1M LP Gas Tankless Water Heater are designed to meet ANSI Z21.10.3-2004 and CSA 4.3-2004 and are certified by the Canadian Standards Association (CSA) to meet these standards for use in recreation vehicles.

  • Page 7: Normal Operation Gswh-1

    The gas control valve of the GSWH-1 and the GSWHAF-1 features a dual BTU solenoid that can operate in HIGH mode (34,000 BTUs) or LOW mode (27,000 BTUs). The BTUs will normally be set to HIGH or LOW depending on the incoming water temperature or normally LOW for summer and HIGH during cooler temperatures.

  • Page 8: Normal Operation Gswh-1M

    NORMAL OPERATION - GSWH-1M The Girard Tankless Water Heater (M-Series), also referred to as an “on demand” water heater, rapidly heats water as it flows around and through the heat exchanger. The output water temperature depends on the temperature of the incoming water and the flow established at the faucet and the dial setting.
  • Page 9 Controlling the Hot Water Temperature 1. The dial makes adjustment to the water temperature very easily. Generally a dial adjustment is all that is required. Turn the dial clockwise to increase the temperature and counter-clockwise to reduce the temperature. 2. If additional adjustment is required, increase or decrease the flow of hot water. Increase the flow to to reduce the temperature slow the flow to increase the temperature.

  • Page 10: Recommended Tools And Equipment

    RECOMMENDED TOOLS AND EQUIPMENT No unusual tools and/or equipment are needed to service the Girard Tankless Water Heater. The following equipment is commonly used for service and is readily available. Be sure that all instruments are regularly calibrated. U-Tube or Dial Type Manometer This device is for measuring the gas...

  • Page 11: Removing Controls Housing

    REMOVING CONTROL HOUSING No unusual tools and/or equipment are needed to service the Girard Tankless Water Heater. The following equipment is commonly used for service and is readily available. Be sure that all instruments are regularly calibrated. To gain easy access to the serviceable components of the Water Heater you must first remove the Controls’...

  • Page 12: Schematics And Diagrams

    SCHEMATICS AND DIAGRAMS Figure 4 Ladder Diagram GSWH-1 Figure 5 Ladder Diagram GSWH-1M P a g e...

  • Page 13: Wiring Diagrams

    Please refer to the electrical diagram for a functional understanding of the electrical components and of the Circuit Board control functions. Wiring Diagrams Wiring Diagram GSWH-1 Figure 6 Wiring Diagram GSWH-1M Figure 7 P a g e...

  • Page 14: Circuit Board Operation

    CIRCUIT BOARD OPERATION When the user opens a Hot Water faucet, water starts flowing through the unit and activates the Flow Switch which in turn activates the Relay; this applies 12VDC power to the ECO (Emergency Cut-Off Thermostat) and to the “Heat Demand” Connection (5) of the Circuit Board (see below). Change to: ….ECO (Emergency Cut-Off Thermostat) and to the ‘TH’...

  • Page 15: Troubleshooting Guide/ Exploded Views

    TROUBLE SHOOTING GUIDE This section includes the most common symptoms that may be found in a model GSWH-1 that is not operating normally. Please refer to the following drawing to locate the components in the unit: Limit Switch Blower Motor Assembly Support...
  • Page 16 Whenever the Circuit Board senses flame during the ignition trials, sparking stops and the Gas Valve remains energized. The Water Flow Switch, the Sail Switch and the Burner flame are constantly monitored to assure that the system continues to operate properly. When the Hot Water faucet is closed and the Flow Switch opens, the demand for heat ends and the Gas Valve is de-energized immediately;...

  • Page 17: Component Information

    COMPONENT INFORMATION On/Off Switch • Confirm power on incoming side of switch. No power check for blown fuse, broken or disconnected wire, low battery Etc. • Power coming into switch but not coming out, Replace Switch. RELAY, with on/off switch turned on •...
  • Page 18 ECO/ (ECO-Combo, later models) To test the ECO with a meter or test lite. When the water heater is turned on, test for power into the switch, from the relay. If no power, go back to the previous information for the relay. If there is incoming power, check the other side of the switch.
  • Page 19 • If it is not stuck, check for low voltage, or hard to operate switch. If the water heater comes on one time, but will not start the second time, check to see that the sail switch is not stuck in the forward position, when the water heater shuts off.
  • Page 20 WATER PRESSURE Since a tankless water heater produces water instantly it should have at least 1 gallon a minute through the hot water lines for good operation. The M-Series is less critical, due to the dial. There are several factors to consider if the water pressure is low: 1.
  • Page 21 Drill sizes for orifices: Series1- # 73 Series M - # 71 If a thorough cleaning fails to resolve the problem, replace entire burner assembly. ELECTRODE If the water heater is not igniting, but you can smell gas through the exhaust flue. 1.

  • Page 22: Gas Modulation Explanation And Testing

    GSWH-1M Gas Modulation & Winter Use Device Systems Specifications & Testing GSWH-1M Temperature Dials The gas modulator temperature dials may appear the same but it is crucial that you confirm the dial is the correct resistance for the gas modulator control board. Using the incorrect temperature dial will cause incorrect voltages to the gas modulator valve.
  • Page 23 1 K Modulator Control Board: It is impossible to identify the difference between the gas modulator control board for a 1K and a 2.2 K system by the size and shape of the box. The color of the wires going to the board will confirm the type of board.
  • Page 24 Gas Modulator System Specifications and Testing Differentiate between the 1K and 2.2K systems by the color of the wires at the gas modulator valve. Orange and black wires identify the system as a 1K system. White and black wires identify the system as a 2.2 K system.
  • Page 25 Gas Modulator Valve Coil resistance should be between 40 and 50 ohms. The orange (1K system) or white (2.2K system) wire on the gas modulator valve coil is 12 VDC + supplied directly from the gas modulator board. The black wire is chassis ground. As the voltage increases the valve decreases the amount of gas flow through the gas modulator valve decreasing the output BTU’s and decreasing the temperature rise.

  • Page 26: Circuit Board Troubleshooting

    CIRCUIT BOARD TROUBLESHOOTING The Circuit Board is the electronic controller for the Water Heater. It is very reliable but it is often diagnosed improperly and replaced. Note: in all cases the replacement of the Circuit Board is the last item. We provide here a list of symptoms and their possible causes to help you to determine if the problem is due to a malfunction of the board or other components.

  • Page 27: General Failures And Possible Causes And Remedies

    6. Flame okay during trial for ignition (TFI), no flame sense (after TFI) a. Check Electrode and High Voltage Wire for Continuity b. Poor ground at burner c. Bad circuit board (check flame current); CONFIRM with Approved Board Tester such as Fenwal part # 05-080224-009) - Replace GENERAL FAILURES AND POSSIBLE CAUSES AND REMEDIES 1.
  • Page 28 4. Water Heater Lockout – Gas present but no Spark a. High Tension Lead Wire Loose: Secure Wire Connection on Circuit Board b. Poor Ground Connection at Burner: Secure Ground Connection to Main Burner c. Improper Electrode Gapping: Re-position Spark Gap Between Electrode Tip and Burner Blade to 1/8˝...

  • Page 29: Routine Maintenance

    ROUTINE MAINTENANCE We recommend that the GSWH-1 water heater be inspected regularly by the user and at least once a year by a qualified service technician. Before an inspection make sure that the LP Gas and Water supply are connected and turned on.

  • Page 30: Winterization

    WINTERIZATION Freezing of the water heater and its plumbing components will result in severe damage that is not covered by warranty. For this reason it is not advisable to use the standard unit (Part# 1GWH) in the winter without installing the Winter Use Device (See below for Winter Use Device option).

  • Page 31: Parts Breakdown

    1GWH6700 Door Assembly 1GWH4400 Door Flange 1GWH4300 Flue Exhaust tube 1GWH4700 Winter Use Device for GSWH-1 (Aftermarket) 1GWH9404 Conversion Flange for Atwood 6 Gallon Polar White 1GWHDA6 Conversion Flange for Atwood or Suburban 10 Gallon Polar White 1GWHDAS10 Figure 10...

  • Page 32: Flat Rate Schedule

    • For any component replacement that does not appear on the above list, contact Girard Products LLC for authorization and instructions. • To process a warranty claim the Service Center must be an authorized Girard Products, LLC Service Center. • Authorized Service Centers must obtain prior approval for work that exceeds the flat rate time allowances.

  • Page 33: Service Procedures

    1. If your RV has its original water heater and is still under the RV manufacturer’s warranty, follow the steps suggested by your dealer or the manufacturer of your RV. 2. Contact Girard Products Water Heater Service Center or call the Girard Products Technical Support Department at 949-259-4024 or visit our website at: www.greenrvproducts.com for a local recommended service center.

  • Page 34: Addendum (Technical Bulletins/Parts List/General Information)

    Addendum - Technical Bulletins TECHNICAL BULLETIN 040611-A CONVERSION DOOR – PART NUMBER 1GWHDAS10 RE: COMPATIABILITY ISSUE WHEN REPLACING AN ATWOOD 10 GALLON WATER HEATER WITH A FLUSH MOUNT DOOR. It has come to our attention that our 1GWHDAS10 Conversion Door does not cover the corners of the Atwood 10 gallon water heater with a FLUSH MOUNT door.
  • Page 35 Addendum - Technical Bulletins TECHNICAL BULLETIN 052814- A DSI BOARD WITH PIN CONNECTORS The DSI Board for the Girard GSWH-1M has changed from SPADE connectors to PIN connectors. Effective with GSWH-1M serial number 10201. Please be sure to have the GSWH-1M serial number before ordering a DSI Board or Wiring Harness to ensure the proper DSI Board is shipped.
  • Page 36 Addendum - Technical Bulletins TECH BULLETIN 081412-A GSWH-1M DIAL (GMC) CHANGE & IDENTIFICATION (Continued) THE 1ST PRODUCTION OF THE GSWH-1M WATER HEATERS AND GMC DIALS ARE NOT INTERCHANGEABLE WITH ALL FOLLOWING PRODUCTION OF GSWH-1M WATER HEATERS & GMC DIALS. THERE ARE APPROXIMATELY 600 OF THE FIRST PRODUCTION GSWH-1M WATER HEATERS. THEY CAN BE IDENTIFIED BY: •...
  • Page 37 Addendum - GSWH-1 & GSWH-1M Spare Parts List Description Part Number UPC Number Photo Burner Assm. - GSWH-1 1GWH1100 846611000127 (Orifice #73 Drill Bit) Burner Assm. - GSWH-1M 1GWHM1100 846611000134 (Orifice #71 Drill Bit) Burner Bracket Left 1GWH1300 846611000141 Burner Bracket Right...
  • Page 38 Addendum - GSWH-1 & GSWH-1M Spare Parts List Description Part Number UPC Number Photo Power Switch 1GWH6700 846611000233 LED Light 1GWH6900 846611000240 GMC Dial - Black 1K 1GWHM6700 846611000257 GMC Diall - White 1K 1GWHM6701 846611000264 GMC Dial - Black 2K...
  • Page 39 Addendum - GSWH-1 & GSWH-1M Spare Parts List Description Part Number UPC Number Photo Hot Water Assm. 1GWH5550 846611000349 w/Valve (1 Plate) Hot Water Assm. w/Valve 1GWH5500 846611000356 (Combo Plate) Flow Switch Assembly 1GWH7100 846611000363 ECO 50C 1GWH6500 846611000370 ECO 55C...
  • Page 40 Addendum - GSWH-1 & GSWH-1M Spare Parts List Description Part Number UPC Number Photo Gas Mod. Solenoid 1GWHM10 846611000455 GSWH-1M Gas Control Valve 1GWH6100 846611000462 GSWH-1 Gas Control Valve 1GWHM6100 846611000479 GSWH-1M Gas Inlet and Tube 1GWH5400 846611000486 Wire Harness - w/DSI wires...
  • Page 41 Addendum - General Information DOOR/FLANGE ASSEMBLIES DOOR/FLANGE ASSEMBLY Part # 1GWHD - POLAR WHITE For new installations. Also applicable conversion door for the Suburban 6 gallon water heater. DOOR/FLANGE ASSEMBLY Part # 1GWHD - POLAR WHITE For new installations. Also applicable conversion door for the Suburban 6 gallon water heater.
  • Page 42 The existing cut-out for a 6 gal. Atwood water heater measures 16 1/4” (W) x 12 5/8” (H). The cut out needed for your GSWH-1 is only 12 ¾” x 12 ¾” and its flange MUST be supported on all sides by a wooden frame so that it may be mounted rigidly with #8 ¾”...

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