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Service Handbook
COMMERCIAL / RESIDENTIAL GAS WATER HEATERS
FOR MODELS:
SHE 50-100 NE, SHE 50-100 PE
GP650 YTPDT, GP650 HTPDT
SERIES 120 & 121
500 Tennessee Waltz Parkway
Ashland City, TN 37015
INSTALLATION CONSIDERATIONS - PRE SERVICE
CHECKS - WATER HEATER CONSTRUCTION -
OPERATION & SERVICE - TROUBLESHOOTING
SERVICING SHOULD ONLY BE PERFORMED BY A QUALIFIED SERVICE AGENT
PRINTED IN THE U.S.A. 0410
318557-000
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Summary of Contents for State Water Heaters SHE 50-100 NE
- Page 1 Service Handbook COMMERCIAL / RESIDENTIAL GAS WATER HEATERS FOR MODELS: SHE 50-100 NE, SHE 50-100 PE GP650 YTPDT, GP650 HTPDT SERIES 120 & 121 500 Tennessee Waltz Parkway Ashland City, TN 37015 INSTALLATION CONSIDERATIONS - PRE SERVICE CHECKS - WATER HEATER CONSTRUCTION - OPERATION &...
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Page 3: Table Of Contents
TABLE OF CONTENTS TABLE OF CONTENTS ................1 ............37 INTRODUCTION ..................2 ..........37 ..................2 ..........39 ................2 ......40 ................2 ........... 41 ................... 2 ........... 42 INSTALLATION CONSIDERATIONS ............. 3 ................44 ................3 ..........45 .............. -
Page 4: Introduction
INTRODUCTION QUALIFICATIONS QUALIFIED INSTALLER OR SERVICE AGENCY ANSI Z223.1 2006 Sec. 3.3.83: SERVICE WARNING SERVICE REMINDER TOOLS REQUIRED... -
Page 5: Installation Considerations
INSTALLATION CONSIDERATIONS INSTRUCTION MANUAL CLOSED WATER SYSTEMS THERMAL EXPANSION AIR REQUIREMENTS CONTAMINATED AIR... - Page 6 VENTING GENERAL VENTING INFORMATION Category IV Appliance MAXIMUM EQUIVALENT LENGTH REQUIREMENTS = 5 linear feet of pipe 2” = 5 linear feet of pipe 3” TABLE 1 2 Inch Pipe 3 Inch Pipe PIPE SIZE REQUIREMENTS MAXIMUM ELBOW REQUIREMENTS...
- Page 7 FACTORY SUPPLIED/INSTALLED FITTINGS INTAKE AIR CONNECTION Blocked Air Intake Blocked Air Intake Blocked Air Intake Blocked Air Intake INTAKE AIR CONNECTION INTAKE AIR 24 VOLT CONNECTION GAS VALVE INTAKE AIR SCREEN MUST CONNECTION ELBOW BE REMOVED ON DIRECT VENT INTAKE AIR INSTALLATIONS HOSE BARB CONNECTION...
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Page 8: Electrical Requirements
ELECTRICAL REQUIREMENTS GROUNDING AND POLARITY MUST BE MUST BE AC Reversed Ignition Failure 120 VAC POWER SUPPLY POLARITY CORRECT WIRING 120 VAC WALL OUTLET NEUTRAL GROUND (typically black) (typically white) (typically green) NEUTRAL GROUND PLUG IN OUTLET TESTER 120 VOLTS 0 VOLTS 120 VOLTS POWER SUPPLY TEST... -
Page 9: Installation Check List
INSTALLATION CHECK LIST Blocked Exhaust Blocked Air Intake Blocked Exhaust Blocked Air Intake Blocked Exhaust Blocked Air Intake Blocked Exhaust AC Reversed Ignition Failure... -
Page 10: Front View
FEATURES AND COMPONENTS FRONT & BACK VIEWS FRONT VIEW BACK VIEW TOP COVER 2 INCH PVC INTAKE AIR CONNECTION ON / OFF SWITCH HEATING LOOP SUPPLY LINE (user interface module) CONNECTION 3/4 INCH NPT CONTROL INTERFACE COVER. TEMPERATURE TEMPERATURE PROBE - LOCATED PRESSURE BEHIND CONTROL RELIEF VALVE... -
Page 11: Top View
TOP VIEW 1/2 INCH BLOCKED SUPPLY GAS INTAKE AIR 2 INCH PVC SECOND CONNECTION SWITCH INTAKE AIR ANODE ROD CONNECTION COMBUSTION 2 INCH PVC BLOWER VENT CONNECTION JUNCTION BOX - 120 VAC BLOCKED POWER SUPPLY EXHAUST CONNECTIONS SWITCH BLOWER PROVER 3/4 INCH NPT SWITCH WATER INLET... -
Page 12: Operation And Service
OPERATION AND SERVICE HOW IT WORKS INTERNAL VIEW BLOWER/BURNER COMBUSTION GAS VALVE AIR INTAKE ASSEMBLY CONNECTION ARROWS SHOW PATH OF FLUE HELICAL SHAPE GASES THROUGH HEAT EXCHANGER THE HEAT EXCHANGER EXHAUST/VENT OUTLET... - Page 13 COMBUSTION BLOWER Service Note: Ignition Failure COMBUSTION BLOWER ASSEMBLY 5 PIN BLOWER WIRING HOUSING SOCKET BLOWER MOTOR AND ELECTRONIC SPEED CONTROL 3 PIN WIRING SOCKET...
- Page 14 BURNER ASSEMBLY BURNER ASSEMBLY RIGHT SIDE VIEW BURNER ADAPTER BURNER BURNER WIRING HARNESS FLANGE & IGNITER/FLAME GASKET SENSOR BLOWER BURNER FLAME FLANGE ADAPTER SENSOR BURNER ASSEMBLY LEFT SIDE VIEW BURNER ADAPTER BURNER BURNER WIRING HARNESS FLANGE & IGNITER/FLAME GASKET SENSOR BLOWER BURNER IGNITER...
- Page 15 BURNER ADAPTER WIRING HARNESS IGNITER/FLAME SENSOR BURNER GROUND WIRE BURNER BLOWER FLANGE WITH BLOWER ADAPTER DISCHARGE ORIFICE IN PLACE BURNER SIGHT GLASS BLOWER DISCHARGE ORIFICE BURNER ADAPTER WIRING HARNESS IGNITER/FLAME SENSOR BLOWER FLANGE WITH ORIFICE REMOVED BLOWER BURNER ADAPTER BLOWER DISCHARGE WIRING HARNESS FLANGE...
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Page 16: Combustion Blower And Burner Removal
COMBUSTION BLOWER AND BURNER REMOVAL Ignition Failure ORANGE SILICONE GASKET BETWEEN THE COMBUSTION WHITE FIBER GASKET BETWEEN THE BURNER ADAPTER AND THE BLOWER AND THE BLOWER FLANGE ON THE BURNER ADAPTER THE HEAT EXCHANGER FLANGE ON TOP OF THE STORAGE TANK COMBUSTION BLOWER REMOVAL... - Page 17 COMBUSTION BLOWER INSTALLATION COMBUSTION BLOWER ASSEMBLY TOP VIEW VENTURI COMBUSTION BLOWER OUTLET SENSING PORT HOSE CLAMP 24 VOLT GAS VALVE INTAKE AIR WIRING HARNESS ELBOW SPADE CONNECTORS COMBUSTION BLOWER 24 VOLT GAS VALVE SUPPLY GAS CONNECTION INTAKE AIR CONNECTION FITTING...
- Page 18 BURNER ASSEMBLY REMOVAL...
- Page 19 BURNER ASSEMBLY INSTALLATION BURNER SIGHT GLASS TWO PHILLIPS HEAD WIRING HARNESS COVER SCREWS HOLD COVER PLATE AND GASKET. PLATE AND GASKET IN PLACE. BURNER FOUR 1/2 INCH GROUND NUTS AND STUDS WIRE...
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Page 20: Flame Sensor
FLAME SENSOR FLAME SENSING OPERATION The Burner MUST BE CONTROL SYSTEM APPLIES AC VOLTAGE TO FLAME SENSOR FLAME SENSOR IGNITER CERAMIC INSULATOR METAL CONDUCTOR AC VOLTAGE FLOWS FROM THE FLAME SENSOR TO THE BURNER. THE BURNER MUST BE GROUNDED FOR CURRENT TO BURNER FLOW. - Page 21 FLAME SENSING CURRENT TEST FLAME SENSING TEST BEHIND FLAME SENSING TEST INSIDE THE CCB ENCLOSURE THE CCB ENCLOSURE IGNITER/FLAME SENSOR CCB J4 FLAME SENSOR WIRING HARNESS FROM CCB CONNECTION WIRE FROM FLAME SENSOR WIRE FROM FLAME SENSOR FLAME SENSOR CERAMIC INSULATOR Ignition Failure Ignition Failure...
- Page 22 IGNITER Low Igniter Current IGNITER CURRENT TEST...
- Page 23 IGNITER CURRENT TEST AT J5 SOCKET ON CCB IGNITER CURRENT TEST BEHIND CCB ENCLOSURE...
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Page 24: Venturi
VENTURI 24 VOLT GAS VALVE GAS INLET BLOWER VENTURI INLET VENTURI Negative Pressure BLOWER Velocity Increases Combustion Air At Constriction Point Pressure Drops Negative Pressure BURNER SUPPLY GAS... -
Page 25: Gas Valve
GAS VALVE 24 VOLT GAS VALVE ASSEMBLY TOP VIEW 24 VOLT GAS VALVE WIRING VENTURI 24 VAC FROM THE J6 SOCKET HARNESS PLUG. 24 VAC ON THE CCB CONNECTS TO FROM CCB IS RECTIFIED TO THESE TWO SPADE TERMINALS 24 VDC BY ELECTRONICS AT THE END OF THE 24 VOLT INSIDE THE PLUG END. - Page 26 GAS VALVE REMOVAL 5/32 INCH GAS ORIFICE 24 VOLT GAS VALVE HEX WRENCH & GASKET VENTURI GAS ORIFICE GASKET GAS ORIFICE SIZES NATURAL GAS: 0.191” PROPANE GAS: 0.162”...
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Page 27: Gas Pressure
GAS PRESSURE TABLE 2 NATURAL GAS PROPANE GAS NATURAL GAS PROPANE GAS NATURAL GAS PROPANE GAS Ignition Failure PRESSURE SUPPLY GAS 24 VOLT GAS VALVE TEST PORTS CONNECTION COMBUSTION BLOWER CONNECTION COMBUSTION AIR INLET VENTURI... -
Page 28: Gas Pressure Test
GAS PRESSURE TEST SUPPLY GAS PRESSURE MANIFOLD OFFSET TEST PORT PRESSURE TEST PORT... - Page 29 GAS FLOW TEST CONDITIONS: GAS: CONDITIONS: GAS: TING CONDITIONS: GAS:...
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Page 30: Pressure Switches
PRESSURE SWITCHES CONSTRUCTION & OPERATION CONSTRUCTION Normal State Activated State (open switch contacts) (closed switch contacts) Switch Contacts Wiring Terminals Internal Linkage Vent Port Flexible Diaphragm Sensing Port TYPES AND APPLICATION Normal State Activated State Blower Prover Pressure Switch Normally open contacts , close on a rise in pressure . - Page 31 CONTROL SYSTEM MONITORING Blower Prover Failure Blower Prover Open Blocked Air Intake Blocked Exhaust PRESSURE SWITCH FAULT MESSAGES Blower Prover Failure Blower Prover Open Fault occurred 2 mins ago Fault occurred 2 mins ago The blower prover switch is The blower prover switch remains closed out of sequence.
- Page 32 Blower Prover Open, Blower Prover Failure, Blocked Air Intake Blocked Exhaust PRESSURE SWITCH SENSING TUBE CONNECTIONS BLOWER PROVER BLOCKED INTAKE AIR BLOCKED EXHAUST BLOCKED EXHAUST...
- Page 33 PRESSURE SWITCH TESTS CONTINUITY TEST DURING STANDBY...
- Page 34 CONTINUITY TEST DURING OPERATION PRESSURE TEST DURING OPERATION...
- Page 35 TABLE 3 Blower Prover Blocked Intake Air Blower Prover: IS NOT Blocked Intake Air: IS NOT IS NOT...
- Page 36 BLOWER PROVER SWITCH PRESSURE TEST BLOCKED INTAKE AIR SWITCH PRESSURE TEST BLOCKED EXHAUST SWITCH PRESSURE TEST...
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Page 37: Temperature Probe
TEMPERATURE PROBE ECO HIGH TEMPERATURE LIMIT SWITCH Energy Cut Out (ECO) TEMPERATURE SENSOR Temp Probe Short Temp Probe Open TEMPERATURE SENSOR TEST... - Page 38 WATER TEMPERATURE TEMPERATURE SENSOR RESISTANCE IN OHMS CELSIUS FAHRENHEIT 26,435 11,974 5,862 3,780 3,066 2,503 1,698 1,177 ECO CONTINUITY TEST Energy Cut Out (ECO) Energy Cut Out (ECO)
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Page 39: Control System Hardware
CONTROL SYSTEM HARDWARE COMPONENTS BUTTON PAD OVERLAY J2 SOCKET - CCB J3 SOCKET - BUTTON COMMUNICATION PAD COMMUNICATION CAT V CABLE J3 SOCKET - ENSURE CABLE IS PLUGGED IN UIM CIRCUIT BOARD BACK EXACTLY AS SHOWN LCD SCREEN UIM CIRCUIT BOARD FRONT... - Page 40 UIM RIBBON CABLE CONNECTION RIBBON CABLE PLUG END METAL CRIMP CONNECTIONS FRONT SIDE BACK SIDE...
- Page 41 CCB ENCLOSURE WITH FRONT REMOVED CCB CIRCUIT BOARD 120 VAC X 24 VAC 50 VA TRANSFORMER CCB ENCLOSURE CCB ENCLOSURE COVER SCREWS (2) TRANSFORMER COVER CCB CIRCUIT BOARD MOLDED CLIPS RAISED EDGES (3) FOR WIRING STRAIN RELIEF FRONT TOP OF WATER HEATER FRONT COVER ON FRONT COVER REMOVED...
- Page 42 CCB COVER REMOVAL AND REPLACEMENT...
- Page 43 CCB CIRCUIT BOARD LAYOUT CCB (CENTRAL CONTROL BOARD) 1 Retry Retries Input Type Tstat Vent Spare Spare S1 DIPSWITCH S1 DIPSWITCH DETAIL 1 Retry Retries Input Type Tstat Vent Spare Spare Dipswitch Operation: Along one side of the dipswitch array there are numbers, 1-4. On the other side of the dipswitch is the word “OPEN.”...
- Page 44 CCB CONNECTION IDENTIFICATION PIN # DESCRIPTION PIN # DESCRIPTION PIN # DESCRIPTION 120 VAC neutral PIN # DESCRIPTION 120 VAC neutral PIN # DESCRIPTION...
- Page 45 PIN # DESCRIPTION J13 Socket - Blower Speed Control PIN # DESCRIPTION...
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Page 46: Wiring Diagram
WIRING DIAGRAM 24 VOLT BLOCKED BLOCKED BLOWER GAS VALVE INTAKE AIR EXHAUST PROVER ENABLE/DISABLE CIRCUIT JUMPER WIRE BETWEEN PINS 8 AND 11 ON J6 PLUG HOT SURFACE IGNITER 1 BLACK 2 WHITE FLAME SENSOR 1 RED (ECO) 2 BLACK 3 BLACK TEMPERATURE PROBE 4 RED (ECO) PWM (Pulse Width Modulation) -
Page 47: Overview
CONTROL SYSTEM OPERATION OVERVIEW CONTROL SYSTEM FEATURES EMI / RFI Filtering:... - Page 48 COMMERCIAL AND RESIDENTIAL MODELS CONTROL SYSTEM NAVIGATION USER INPUT BUTTONS DESKTOP SCREEN UIM (user interface module) Desktop Screen Shown LCD Screen Title Bar MANUFACTURER / MODEL INFORMATION Information Tank Temperature 103°F Display Operating Set Point 120°F Status: Heating Status Icons Up &...
- Page 49 STATUS ICONS TABLE 5 Icon NOTE:...
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Page 50: Control System Menus
OPERATING STATES TABLE 6 State NOTE: Fault NOTE: CONTROL SYSTEM MENUS Heater Status Current Fault NOTE:... - Page 51 TEMPERATURES NOTE: DESCRIPTION/ACTION DISPLAY MANUFACTURER / MODEL INFORMATION Tank Temperature 120°F Operating Set Point 120°F Status: Standby MENU HELP Main Menu Temperatures Heater Status Display Settings Heater Information Current Fault SELECT BACK HELP Temperatures Operating Set Point 120°F Differential 8°F Tank Temperature 120°F Tank Probe Offset...
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Page 52: Heater Status
TEMPERATURES MENU DESCRIPTION/ACTION DISPLAY Temperatures Operating Set Point 140°F Differential 8°F Tank Temperature 120°F Tank Probe Offset 0°F CHANGE BACK HELP NOTE: HEATER STATUS DESCRIPTION/ACTION DISPLAY Heater Status Status Standby ECO Contact Closed Blocked Inlet PS Closed Blocked Outlet PS Closed ECO Contact, Blocked Inlet PS, Blower Prover PS... - Page 53 DISPLAY SETTINGS DESCRIPTION/ACTION DISPLAY Display Settings Temperature Units °F Backlight Delay Contrast Backlight Delay CHANGE BACK HELP NOTE: HEATER INFORMATION DESCRIPTION/ACTION DISPLAY Heater Information Elapsed Time 10 day 0 hrs 0 mins Burner On Time 5 hrs 22 mins Cycle Count 00000035 CCB Version X.XX...
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Page 54: Current Fault
CURRENT FAULT DESCRIPTION/ACTION DISPLAY Blocked Exhaust Fault occurred 2 mins ago The exhaust is blocked or restricted. Ensure condensate hose is draining. Call a service professional: Your Company Name Here (press [DOWN] for more..) CHANGE BACK ADVANCED FAULT HISTORY DESCRIPTION/ACTION DISPLAY Fault History Blocked Air Intake (A7) - Page 55 SERVICE CONTACT INFORMATION DESCRIPTION/ACTION DISPLAY Service Contact Information Show Contact Information Change Contact Name Change Contact Phone Current Contact Info: (000) 000-0000 Access Code CHANGE BACK HELP Service Contact Information Show Contact Information Change Contact Name Change Contact Phone Current Contact Info: (000) 000-0000 NOTE: Access Code...
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Page 56: Sequence Of Operation
SEQUENCE OF OPERATION the Blower Prover Open Low Igniter Current Ignition Failure... -
Page 57: Sequence Of Operation Flow Chart
SEQUENCE OF OPERATION FLOW CHART If tank temperature drops below Operating Set Point minus Differential setting a heating cycle is activated Control System performs diagnostic system check Control System Locks Out Normal State of all pressure switches and ECO are checked Blower Prover pressure is switch verified open Displays Fault Msg All other pressure switches and ECO are verified closed... -
Page 58: Troubleshooting
TROUBLESHOOTING ROUGH STARTING/ROUGH OPERATION NOT ENOUGH HOT WATER HEATER STATUS MENU THINGS TO CHECK BEFORE SERVICING NOTE: RESETTING THE CONTROL SYSTEM IMPORTANT SERVICE REMINDER... -
Page 59: Control System Unresponsive
CONTROL SYSTEM UNRESPONSIVE DISPLAYED MESSAGE/CONDITION/INDICATES POSSIBLE CAUSES - CHECK/REPAIR water heater. -
Page 60: Ac Reversed
FAULT MESSAGES DISPLAYED MESSAGE/CONDITION/INDICATES POSSIBLE CAUSES - CHECK/REPAIR AC Reversed Fault occurred 2 mins ago Power supply to water heater has reversed polarity. Call a service professional: Your Company Name Here (press [DOWN] for more..) ADVANCED CHANGE BACK Temp Probe Open Fault occurred 2 mins ago There is a problem with the temperature probe. -
Page 61: Fault Messages
FAULT MESSAGES DISPLAYED MESSAGE/CONDITION/INDICATES POSSIBLE CAUSES - CHECK/REPAIR Flame Sensor Short Fault occurred 2 mins ago The flame sensor is grounded. Call a service professional: Your Company Name Here (press [DOWN] for more..) ADVANCED CHANGE BACK Flame Detect Error Fault occurred 2 mins ago Flame detected out of sequence. - Page 62 FAULT MESSAGES DISPLAYED MESSAGE/CONDITION/INDICATES POSSIBLE CAUSES - CHECK/REPAIR DO NOT LEAVE Energy Cut Out (ECO) THE WATER HEATER IN OPERATION UNDER ANY Fault occurred 2 mins ago Tank temperature is excessive. The water heater has been disabled. Call a service professional: Your Company Name Here (press [DOWN] for more..) CHANGE...
- Page 63 FAULT MESSAGES DISPLAYED MESSAGE/CONDITION/INDICATES POSSIBLE CAUSES - CHECK/REPAIR Blocked Air Intake Blocked Air Intake Fault occurred 2 mins ago The combustion air intake is restricted. Call a service professional: Your Company Name Here (press [DOWN] for more..) CHANGE BACK ADVANCED...
- Page 64 FAULT MESSAGES DISPLAYED MESSAGE/CONDITION/INDICATES POSSIBLE CAUSES - CHECK/REPAIR Blocked Exhaust Fault occurred 2 mins ago The exhaust is blocked or restricted. Ensure condensate hose is draining. Call a service professional: Your Company Name Here (press [DOWN] for more..) CHANGE BACK ADVANCED Blower Prover Failure Fault occurred 2 mins ago...
- Page 65 FAULT MESSAGES DISPLAYED MESSAGE/CONDITION/INDICATES POSSIBLE CAUSES - CHECK/REPAIR Blower Prover Open PERFORM ALL THESE TESTS WITH POWER TURNED ON AND A CALL FOR HEAT ACTIVE. Blower Prover Open Fault occurred 2 mins ago The blower prover switch remains open after the blower has been energized.
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Page 66: Low Igniter Current
FAULT MESSAGES DISPLAYED MESSAGE/CONDITION/INDICATES POSSIBLE CAUSES - CHECK/REPAIR Low Igniter Current Fault occurred 2 mins ago Igniter current is low. Call a service professional: Your Company Name Here (press [DOWN] for more..) CHANGE BACK ADVANCED... - Page 67 FAULT MESSAGES DISPLAYED MESSAGE/CONDITION/INDICATES POSSIBLE CAUSES - CHECK/REPAIR Ignition Failure Fault occurred 2 mins ago The water heater has failed to ignite the burner. Call a service professional: Your Company Name Here (press [DOWN] for more..) CHANGE BACK ADVANCED PROCEED TO THE NEXT PAGE...
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Page 68: Communication Failure
FAULT MESSAGES DISPLAYED MESSAGE/CONDITION/INDICATES POSSIBLE CAUSES - CHECK/REPAIR Ignition Failure Ignition Failure Fault occurred 2 mins ago The water heater has failed to ignite the burner. Call a service professional: Your Company Name Here (press [DOWN] for more..) CHANGE BACK ADVANCED Communication Failure Fault occurred 2 mins ago... - Page 69 NOTES...
- Page 70 NOTES...
- Page 72 500 Tennessee Waltz Parkway, Ashland City, TN 37015...
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