Related Manuals for State Water Heaters GP650 HTPDT
Summary of Contents for State Water Heaters GP650 HTPDT
- Page 1 COMMERCIAL / RESIDENTIAL GAS WATER HEATERS SERVICE HANDBOOK ULTRA HIGH EFFICIENCY POWER VENT / POWER DIRECT VENT FOR MODELS: • SHE50-100 NE • SHE50-100 PE • GP650 YTPDT • GP650 HTPDT PRINTED 0308 198148-000...
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Page 2: Table Of Contents
POWER VENT/POWER DIRECT VENT INTRODUCTION ... 2 Qualifications ... 2 Service Warning ... 2 Important Service Reminder ... 2 Instruction Manual ... 3 Tools Required... 3 INSTALLATION CONSIDERATIONS ... 4 Closed Water Systems ... 4 Thermal Expansion... 4 Air Requirements ... 5 Contaminated Air ... -
Page 3: Introduction
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL INTRODUCTION This Service Manual is designed to be an aid in servicing and troubleshooting the 96% thermally efficient, 50 gallon, 100,000 Btu/hr residential and light duty commercial power vent - power direct vent model water heaters listed on the cover of this manual.The instructions, illustrations and procedures contained in this manual are used to verify proper operation and to diagnose and repair common service problems. -
Page 4: Instruction Manual
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL INSTRUCTION MANUAL Have a copy of the Instruction Manual that came with the water heater on hand for the correct model water heater you are working with before servicing. Installation information given in this Service Manual is not a complete installation instruction. -
Page 5: Installation Considerations
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL INSTALLATION CONSIDERATIONS INSTRUCTION MANUAL Installation information given in this Service Manual is not a complete installation instruction. Installation information covered in this Service Manual has a limited focus as it applies to servicing. -
Page 6: Air Requirements
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL AIR REQUIREMENTS Carefully review the requirements for combustion and ventilation air in the Instruction Manual that came with the water heater. Failure to meet these requirements when the water heater is installed or overlooking their importance when servicing the water heater often results in needless down time, unnecessary parts replacement, and customer dissatisfaction. -
Page 7: Venting
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL VENTING The venting information presented in this Service Manual is not a complete venting installation instruction. Refer to the Instruction Manual that came with the water heater for complete installation instructions. The water heater covered in this Service Manual may be installed as a conventionally vented water heater or as a direct vent water heater. - Page 8 ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL VENTING (CONT) Pipe Size Requirements Ensure the correct size pipe has been used for the overall equivalent length of the vent and intake air piping installed. Longer equivalent lengths require larger pipe sizes, see Table 1. Maximum Elbow Requirements Three and four inch vent and intake air pipe installations allow a maximum of 6 - 90°...
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Page 9: Electrical Requirements
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL ELECTRICAL REQUIREMENTS The water heater covered by this Service Manual must be grounded in accordance with the local codes, or in the absence of local codes: the National Electrical Code (NFPA 70) or the Canadian Electrical Code (C22.1). -
Page 10: Operation & Service
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL OPERATION & SERVICE HOW IT WORKS This section of the Service Manual will cover operation, common service procedures and water heater construction. The water heater covered in this Service Manual has a helical coil shaped heat exchanger that is submerged in the storage tank. -
Page 11: Blower
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL BLOWER The blower is an assembly consisting of the blower housing, motor and an integrated VFD (variable frequency drive). Blower operation is controlled by the CCB (central control board - page 35). The CCB sends 120 VAC to the Blower/VFD assembly high voltage 3 pin socket. -
Page 12: Burner
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL BURNER The images below show a complete blower/burner assembly removed along with a top view of the water heater with the blower removed. Service Notes - Burner (Flame Sensor) The burner installed in the water heater is a radial fire burner. Radial fire burners can trap debris that enter the blower. -
Page 13: Continued On Next Page
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL BURNER (CONT) Burner & Blower Removal The burner should be removed and inspected whenever service is being performed for rough operation or ignition failure. Radial fire burners like the one used on this water heater can trap debris, see Service Notes - Venting on page 7. - Page 14 ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL BURNER (CONT) Burner/Blower Removal (cont) 1/4” Hex Machine Screws Service Notes - Blower Flange & Blower Adapter Gaskets. Whenever the blower or burner is removed for service DO NOT overtighten the machine screws that hold the blower flange to the blower adapter (page 12) or the blower adapter to the water heater tank (above).
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Page 15: Venturi
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL VENTURI A Venturi is connected to the inlet of the blower. All combustion air flows through the Venturi. The outlet of the 24 VAC gas valve connects directly to the side of the Venturi. Fuel gas flows from the outlet of the gas valve into the side of the Venturi directly. -
Page 16: Gas Valve
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL GAS VALVE The outlet of the gas valve is connected by flange directly to the side of the Venturi (page 14). There is no manifold gas line on the water heater. A gas orifice with gasket is fitted into the gas valve’s outlet flange. -
Page 17: Gas Pressure Testing
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL GAS PRESSURE TESTING The water heater covered in this Service Manual is rated at 100,000 Btu/hr input. It is certified for elevations up to 10,100 feet (3079 meters) without adjustment. Call the technical support phone number shown on the water heater labeling before operating the water heater at higher elevations. - Page 18 ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL GAS PRESSURES (CONT) Typical manifold and supply gas pressures during: 1 Standby Mode 2 Pre-Purge Mode 3 Heating Mode 1 BLOWER OFF / GAS VALVE OFF Manifold 0.00” W.C. Supply +9.70” W.C. Manifold 2 BLOWER ON / GAS VALVE OFF Manifold -6.86”...
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Page 19: Air Pressure Switches
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL AIR PRESSURE SWITCHES Air pressure switch technical bulletins TB-A023-06 and TB-S023-06 explain air pressure switch construction and test procedures in detail. These technical bulletins are available on the manufacturers web site or by calling the technical support phone number shown on the water heater labeling. -
Page 20: Top View
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL AIR PRESSURE SWITCHES (CONT) The water heater covered in this Service Manual is factory equipped with three air pressure switches. These switches are used to provide verification or prove electrically that the blower is running and that the vent and intake air pipes are not blocked or restricted. -
Page 21: Air Pressure Switch Operation
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL AIR PRESSURE SWITCH OPERATION The control system monitors the “state” of the air pressure switches individually through three separate circuits (see wiring on diagram page 39). The “state” of the switch refers to whether the switch contacts are open or closed. -
Page 22: Air Pressure Switch Testing
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL AIR PRESSURE SWITCH TESTING Air pressure switch testing involves three procedures: • Normal State Test • Operational State Test • Pressure Test Normal State Test Turn off power and disconnect the wires to the pressure switches. Wrap electrical tape around the wire ends to prevent shorts. - Page 23 ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL AIR PRESSURE SWITCH TESTING (CONT) Pressure Test The Pressure Test is necessary when the air pressure switch in question has passed the Normal State Test but failed the Operational State Test (see page 21). This test requires a digital manometer (see Tool Requirements page 3 and the images on page 23).
- Page 24 ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL AIR PRESSURE SWITCH TESTING (CONT) BLOWER PROVER SWITCH PRESSURE TEST BLOCKED INTAKE SWITCH PRESSURE TEST BLOCKED EXHAUST SWITCH PRESSURE TEST Technical Literature Department 23 of 52 Ashland City, TN © 2008 Servicing should only be performed by a Qualified Service Agent...
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Page 25: Flame Sensing Test
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL FLAME SENSING TEST To prove burner flame during ignition the control system monitors flame sensing current through the flame sensor. It is a DC micro amp (µA) current that flows through the flame sensor. -
Page 26: Igniter Current Test
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL IGNITER CURRENT TEST The water heater covered by this Service Manual uses a hot surface igniter (HSI). The control system CCB (page 35) powers the igniter (120 VAC) and monitors igniter current (AC amps). -
Page 27: Control System
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL CONTROL SYSTEM INTRODUCTION This portion of the service manual will cover the control system. The control system includes several components: a UIM (User Interface Module), a CCB (Central Control Board), and an Overlay/Button Pad. -
Page 28: Uim
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL The UIM (User Interface Module) is the display on the front of the water heater. The UIM’s major components include a Circuit Board with LCD display and a Button Pad Overlay which contains the five user input buttons. -
Page 29: Discreet Menu - Contact Information
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL UIM (CONT) User input buttons on the UIM include an Up, a Down, and three Operational buttons. The Up and Down buttons are used to navigate through the various menus and screens displayed and to adjust or change user settings such as the Operating Set Point. -
Page 30: Desktop Screen
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL UIM (CONT) Desktop Screen The Desktop screen is the default screen. If there are no active fault messages the display will return to this screen with no user input after approximately 10 minutes. The Desktop screen displays text and icons that provide operational and diagnostic information. -
Page 31: Status Icon
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL UIM (CONT) Table 4 - Status Icons STATUS ICON DESCRIPTION The temperature of the water in the tank has fallen and the water heater will now initialize a new heating cycle. The temperature of the water in the tank has reached the Operating Set Point. - Page 32 ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL UIM (CONT) Table 5 - Operational States (Modes) STATE The water heater is not in an active heating cycle. This usually means the temperature Standby in the tank has reached Operating Set Point and has not dropped low enough to initiate a call for heat.
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Page 33: Operating Set Point Adjustment
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL OPERATING SET POINT ADJUSTMENT When the temperature sensed by the control system at the Temperature Probe (top of the water heater) reaches the Operating Set Point the control system will end the heating cycle. A call for heat will be activated again when the tank temperature drops below the Operating Set Point minus the Differential setting plus one degree. -
Page 34: Control System Menus
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL CONTROL SYSTEM MENUS Desktop: This is the default screen for the control system. If there are no active faults or warnings the display will return to this screen with no user input after approximately 10 minutes. - Page 35 ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL CONTROL SYSTEM MENUS (CONT) Heater Information: This menu contains historic operational and configuration information. Information/settings available: • Elapsed Time - hrs & mins - how long the water heater has been powered on •...
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Page 36: Ccb
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL The CCB circuit board is the main control. All instructions for ignition and temperature control originate from this circuit board. Diagnostic and operational messages are generated by the CCB and sent to the UIM (page 27). Most of the water heater’s components, such as the igniter, blower, gas valve, and temperature probe are directly connected to one of the CCB’s socket connectors. -
Page 37: Socket Identification
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL CCB (CONT) Socket Identification All wiring connections and sockets will be identified in the following pages. The Troubleshooting section of this Service Manual will refer back to this illustration and information. - Page 38 ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL CCB (CONT) J1 Socket - Transformer PIN # 120 VAC hot to transformer Not used 120 VAC neutral to transformer 24 VAC out from transformer 24 VAC out from transformer J2 Socket - 120 VAC To Blower PIN # 120 VAC hot to blower...
- Page 39 ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL CCB (CONT) J7 Socket - Temperature Probe/ECO (immersion probe - top of the water heater) PIN # ECO (energy cut out) 24 VAC out (red wire) Upper temperature probe (thermistor) +5.0 VDC (black wire) Upper temperature probe (thermistor) -5.0 VDC (black wire) ECO (energy cut out) 24 VAC return (red wire) J9 Port - Communication Port - Not Used...
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Page 40: Wiring Diagram
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL WIRING DIAGRAM Service Notes - Polarity & Ground This water heater is polarity and ground sensitive. The control system will lock out and display a fault message (“AC Reversed”) if the power supply polarity is reversed. Flame sensing current cannot be established if the burner is not grounded which will lead to ignition failure. -
Page 41: Sequence Of Operation
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL SEQUENCE OF OPERATION Call for heat initiated Air Pressure Switch Test Is Performed Blower Prover Switch is verified open Blocked Intake and Blocked Exhaust Switches are verified closed Blower Motor is energized Blower Prover Switch is verified closed Igniter is energized for warm up period (approx 17 seconds) -
Page 42: Troubleshooting
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL TROUBLESHOOTING The control system performs exhaustive self diagnostics and displays detected fault conditions in plain english fault messages on the UIM (page 27) when there is a problem. When the control system declares a fault condition it will “lock out” and disable heating. Troubleshooting procedures for the most common error messages are covered in this manual. -
Page 43: Control System Unresponsive
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL CONTROL SYSTEM UNRESPONSIVE DISPLAYED MESSAGE CONDITION/INDICATES UIM Display Is Blank On/Off is turned off Water heater is not plugged in Tripped Breaker - Blown Fuses 120 VAC power supply problems 24 VAC power supply problems Defective transformer Wiring or plug/socket connection problems... -
Page 44: Fault Messages
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL FAULT MESSAGES DISPLAYED MESSAGE CONDITION/INDICATES “AC Reversed” The control system has detected the power supply polarity is reversed. “Upper Probe Open” The control system has detected over 56,000 ohms from the Temperature Probe on top of the water heater. -
Page 45: Upper Probe Short
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL FAULT MESSAGES (CONT) DISPLAYED MESSAGE CONDITION/INDICATES “Upper Probe Short” The control system has detected less than 390 ohms from the Temperature Probe on top of the water heater. “Flame Probe Short” The control system has detected that the flame sensor is grounded. -
Page 46: Flame Detect Error
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL FAULT MESSAGES (CONT) DISPLAYED MESSAGE CONDITION/INDICATES “Flame Detect Error” The control system has detected flame sensing current out of sequence. “Energy Cut Out (ECO)” The control system has detected water temperature in the tank above 190°F. -
Page 47: Blocked Inlet
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL FAULT MESSAGES (CONT) DISPLAYED MESSAGE CONDITION/INDICATES “Blocked Inlet” The control system has detected open contacts at the Blocked Intake air pressure switch - inadequate supply of intake (combustion) air. Technical Literature Department Servicing should only be performed by a Qualified Service Agent CHECK/REPAIR •... -
Page 48: Blocked Exhaust Vent
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL FAULT MESSAGES (CONT) DISPLAYED MESSAGE CONDITION/INDICATES “Blocked Exhaust Vent” The control system has detected open contacts at the Blocked Exhaust air pressure switch - the water heater is not venting properly. “Blower Prover Failure”... -
Page 49: Blower Prover Open - Blower Not Running
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL FAULT MESSAGES (CONT) DISPLAYED MESSAGE CONDITION/INDICATES “Blower Prover Open” (Blower Not Running) The control system has detected open contacts at the Blower Prover air pressure switch after Blower has been energized. “Blower Prover Open”... -
Page 50: Low Igniter Current
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL FAULT MESSAGES (CONT) DISPLAYED MESSAGE CONDITION/INDICATES “Low Igniter Current” The control system has detected less than 2.0 AC amps through the igniter during the igniter warm up period. Technical Literature Department Servicing should only be performed by a Qualified Service Agent CHECK/REPAIR •... -
Page 51: Ignition Failure
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL FAULT MESSAGES (CONT) DISPLAYED MESSAGE CONDITION/INDICATES “Ignition Failure” The control system has detected less than 1.0 µA (DC micro amps) through the flame sensor during the Ignition Verification operating state on three consecutive trials for ignition. - Page 52 ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL FAULT MESSAGES (CONT) DISPLAYED MESSAGE CONDITION/INDICATES “Ignition Failure” The control system has detected less than 1.0 µA (DC micro amps) through the flame sensor during the Ignition Verification operating state on three consecutive trials for ignition.
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Page 53: Gas Valve Failure
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL FAULT MESSAGES (CONT) DISPLAYED MESSAGE CONDITION/INDICATES “Gas Valve Failure” The control system has not detected any current through the gas valve after it has been energized. “Communication Failure” Loss of communication between the CCB and the UIM. - Page 54 500 Tennessee Waltz Parkway Ashland City, TN 37015...
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