State Water Heaters 197425-004 Instruction Manual
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State Water Heaters 197425-004 Instruction Manual

State Water Heaters 197425-004 Instruction Manual

100 series power vented residential gas water heaters
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Technical Support: 800-365-0024
Parts: 800-821-2017
www.statewaterheaters.com
Low Lead Content
all technIcal and warrantY questIons: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS
PURCHASED. IF YOU ARE UNSUCCESSFUL, PLEASE WRITE TO THE COMPANY LISTED ON THE RATING PLATE ON THE WATER HEATER.
PRINTED 0810
resIdentIal Gas water heaters
Keep thIs Manual In the pocKet on heater for future reference
whenever MaIntenance adjustMent or servIce Is requIred.
power vented Gas Models w/hot surface IGnItIon
NOT FOR USE IN MANUFACTURED (MOBILE) HOMES
Model Gp6 50YIvIt serIes 100
•
AN ODORANT IS ADDED TO THE GAS USED
1

Instruction Manual

for Your safety

BY THIS WATER HEATER.
•
197425-004

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Summary of Contents for State Water Heaters 197425-004

  • Page 1: Instruction Manual

    PRINTED 0810 Instruction Manual power vented Gas Models w/hot surface IGnItIon NOT FOR USE IN MANUFACTURED (MOBILE) HOMES Model Gp6 50YIvIt serIes 100 • for Your safety AN ODORANT IS ADDED TO THE GAS USED BY THIS WATER HEATER. • 197425-004...

  • Page 2: Safe Installation, Use And Service

    safe InstallatIon, use and servIce The proper installation, use and servicing of this water heater is extremely important to your safety and the safety of others. 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.

  • Page 3: General Safety Information

    General safetY InforMatIon...

  • Page 4: General Safety Information

    General safetY InforMatIon at least 18" (45.7 cm) above the floor. This will reduce, but not eliminate, the risk...

  • Page 5: Table Of Contents

    SAFE INSTALLATION, USE AND SERVICE... 2 APPROVALS ... 2 GENERAL SAFETY INFORMATION ...3-4 TABLE OF CONTENTS ... 5 INTRODUCTION ... 5 Qualified Installer or Service Agency ... 5 Preparing for the Installation ... 5 INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS ... 6 TYPICAL INSTALLATION ...7-9 Mixing Valves ...

  • Page 6: Installation Requirements For The Commonwealth Of Massachusetts

    InstallatIon requIreMents for the coMMonwealth of Massachusetts coMMonwealth of Massachusetts For all side wall terminated, horizontally vented power vent, direct vent, and power direct vent gas fueled water heaters installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of...

  • Page 7: Typical Installation

    Get to Know Your water heater - Gas Models a vent pipe B anode c hot water outlet D Outlet (120 VAC) f Gas supply G Main Manual Gas shuttoff valve h Ground joint union j dirt leg K outer door l union M Inlet water shuttoff valve n cold water Inlet...
  • Page 8 tYpIcal InstallatIon condensate hose and draIn pan fIGure 1a.

  • Page 9: Mixing Valves

    MIXInG valve / therMal eXpansIon tanK usaGe and space heatInG MIXInG valves DANGER Water temperature over 125°F (52°C) can cause severe burns instantly resulting in severe injury or death. Children, the elderly and the physically or mentally disabled are at highest risk for scald injury.

  • Page 10: Locating The New Water Heater

    locatInG the new water heater facts to consIder aBout the locatIon Carefully choose an indoor location for the new water heater, because the placement is a very important consideration for the safety of the occupants in the building and for the most economical use of the appliance.

  • Page 11: Insulation Blankets

    in an alcove or closet, the entire floor must be covered by the panel. Failure to heed this warning may result in a fire hazard. Minimum clearances between water heater and combustible construction are 0 inch at the sides and rear, 5.5” (14.0 cm) from the front and 12” (30.5 cm) from top. (Standard clearance.) If clearances stated on the heater differ from standard clearances, install water heater according to clearances stated on the heater. Adequate clearance 24” (61.0 cm) for servicing this appliance should be considered before installation, such as changing the anodes, etc. A minimum clearance of 5.5” (14.0 cm) must be allowed for access to replaceable parts such as thermostats, drain valve, relief valve and condensate drain.

  • Page 12: Unconfined Space

    Such a condition often will result in a yellow, luminous burner flame, causing sooting of the combustion chamber, burners and flue tubes and creates a risk of asphyxiation. Do not install the water heater in a confined space unless an adequate supply of air for combustion and ventilation is brought in to that space using the methods described in the Confined Space section that follows.

  • Page 13: Outdoor Air Through Two Horizontal Ducts

    Figure 7. The water heater should have clearances of at least 1 inch (25 mm) from the sides and back and 6 inches (150 mm) from the front of the appliance. The opening should directly communicate with the outdoors or should communicate through a vertical or horizontal duct to the outdoors or spaces that freely communicate with the outdoors and should have a minimum free area of the following: 1. 1 square inch per 3000 Btu/hr (700 mm rating of all appliances located in the enclosure, and...

  • Page 14: Installing The New Water Heater

    InstallInG the new water heater cheMIcal vapor corrosIon CORROSION OF THE FLUEWAYS AND VENT SYSTEM MAY OCCUR IF AIR FOR COMBUSTION CONTAINS CERTAIN CHEMICAL VAPORS. SUCH CORROSION MAY RESULT IN FAILURE AND RISK OF ASPHYXIATION. Spray can propellants, cleaning solvents, refrigerator and air conditioning refrigerants, swimming pool chemicals, calcium and sodium chloride (water softener salt), waxes, and process chemicals are typical compounds which are potentially corrosive.

  • Page 15: Thermal Expansion

    therMal eXpansIon As water is heated, it expands (thermal expansion). In a closed system the volume of water will grow when it is heated. As the volume of water grows there will be a corresponding increase in water pressure due to thermal expansion.

  • Page 16: High Altitude Installation

    discharge opening must not be blocked or reduced in size under any circumstances. Excessive length, over 30 feet (9.14 m), or use of more than four elbows can cause restriction and reduce the discharge capacity of the valve. No valve or other obstruction is to be placed between the Temperature-Pressure Relief Valve and the tank.

  • Page 17: Sediment Traps

    A gas line of sufficient size must be run to the water heater. Consult the current edition of National Fuel Gas Code (ANSI Z223.1/NFPA 54) and your gas supplier concerning pipe size. There must be: • A readily accessible manual shuttoff valve in the gas supply line serving the water heater, and • A drip leg (sediment trap) ahead of gas control valve to help prevent dirt and foreign materials from entering the gas control valve. • A flexible gas connector or a ground joint union between the shuttoff valve and control valve to permit servicing of the unit.

  • Page 18: Vent Pipe Assembly

    Never use this water heater unless it is completely full of water. To prevent damage to the tank, the tank must be filled with water. Water must flow from the hot water faucet before turning “ON” gas to the water heater. To fill the water heater with water: 1. Close the water heater drain valve by turning handle to the right (clockwise). The drain valve is on the lower front of water heater. 2. Open the cold water supply valve to the water heater. note: the cold water supply valve must be left open when the water heater is in use.

  • Page 19: Vent Pipe Termination

    terMInatIon clearances sIdewall power vent VENT TERMINAL Vent terminal clearances for “Power Vent” installations. Power Vent configurations use room air for combustion. Clearance above grade, veranda, porch, 12 inches (30 cm) deck or balcony Clearance to window or door that may 4 feet (1.2 m) below or to side of opening; 1 be opened foot (30 cm) above opening Clearance to permanently closed window 12 inches (30 cm)*...

  • Page 20: Planning The Vent System

    plannInG the vent sYsteM Plan the route of the vent system from the discharge of the blower to the planned location of the vent terminal. Refer to VAA instruction on page 24 while planning the vent system. 1. Layout total vent system to use a minimum of vent pipe and elbows. 2. This water heater is capable of venting flue gases equivalent to 25’ (7.6 m) of 2” pipe, 65’ (19.8 m) of 3” pipe, or 128’ (39.0 m) of 4” pipe as listed in Table 2.

  • Page 21: Condensate

    The condensate trap may be primed by filling the CONDENSATE U-ASSEMBLY with tap water while the water heater is not operating. The system is fully primed when the water level reaches the adaptor connected into the Tee. In most installations the water heater will self-prime the condensate trap during the first full heat-up cycle. If a sound of air bubbling through water (gurgling) is heard while the blower is operating after the first heat-up cycle, then turn the unit off and contact your plumber or service representative. If these instructions are not followed, the condensate build-up will block the exhaust outlet, which will cause improper operation.
  • Page 22 may be easier to mark both the inside and outside wall. Align holes by drilling a hole through center of the template from the inside through to the outside. The template can now be positioned on the outside wall using the drilled hole as a centering point for the template. 3. A) MASONRY SIDE WALLS Chisel an opening approximately one half inch (1.3 cm) larger than the marked circle.

  • Page 23: Installation Of Vent System, Sidewall

    InstallatIon of vent sYsteM, sIdewall With the route of the venting system and selection of materials completed, as discussed in the section of this manual titled PLANNING THE VENT SYSTEM, the through the wall vent terminal in place and the first section of piping, up to first elbow, installed at the blower it is time to complete the installation of the venting system for the sidewall installation. SNORKEL *MIN.

  • Page 24: Vent Attenuation Assembly Installation Instructions

    vent attenuatIon asseMBlY InstallatIon InstructIons The Vent Attenuation Assembly (VAA) is designed to provide a reduction in fan noise created in the blower wheel. This installation of this VAA is optional. Review directions thoroughly prior to installing the new VAA. Please contact the manufacturer of the water heater as shown in the instruction manual with any questions or for additional product support.
  • Page 25 barb, use a wire tie or hose clamp (not supplied with kit) and secure. 6. Take the other end of the flexible tubing and slide it through the hose clamp on the jacket top cover and install it into one of the four barb fittings in vent pipe assembly #2.

  • Page 26: Vent Pipe Preparation

    vent pIpe preparatIon 1. InItIal preparatIon Make sure the solvent cement you are planning to use is designed for the specific application you are attempting. Know the physical and chemical characteristics and limitations of the PVC and CPVC piping materials that you are about to use. Know the reputation of your manufacturer and their products. D. Know your own qualifications or those of your contractor. The solvent welding technique of joining PVC and CPVC pipe is a specialized skill just as any other pipe fitting technique.
  • Page 27 B. deburring Use a knife, plastic pipe deburring tool, or file to remove burrs from the end of small diameter pipe. Be sure to remove all burrs from around the inside as well as the outside of the pipe. A slight chamfer (bevel) of about 10°-15° should be added to the end to permit easier insertion of the pipe into the end of the fitting. Failure to chamfer the edge of the pipe may remove cement from the fitting socket, causing the joint to leak. step B C. Test dry fit of the joint Tapered fitting sockets are designed so that an interfaced fit should occur when the pipe is inserted about 1/3 to 2/3 of the way into the socket. Occasionally, when pipe fitting dimensions are at the tolerance extremes, it will be possible to fully insert dry pipe to the bottom of the fitting socket. When this happens, a sufficient quantity of cement...

  • Page 29: Temperature Regulation

    teMperature reGulatIon It is recommended that lower water temperatures be used to avoid the risk of scalding. It is further recommended, in all cases, that the water temperature be set for the lowest temperature which satisfies your hot water needs. This will also provide the most energy efficient operation of the water heater. Short repeated heating cycles caused by small hot water uses can cause temperatures at the point of use to exceed the thermostat setting by up to 20°F (11°C). If you experience this type of use you should consider using lower temperature settings to reduce scald hazards.

  • Page 30: For Your Information

    start up condItIons sMoKe/odor It is not uncommon to experience a small amount of smoke and odor during the initial start-up. This is due to burning off of oil from metal parts, and will disappear in a short while. stranGe sounds Possible noises due to expansion and contraction of some metal parts during periods of heat-up and cool-down do not necessarily represent harmful or dangerous conditions.

  • Page 31: Burner Operation And Inspection

    Burner operatIon and InspectIon Flood damage to a water heater may not be readily visible or immediately detectable. However, over a period of time a flooded water heater will create dangerous conditions which can cause DEATH, SERIOUS BODILY INJURY, OR PROPERTY DAMAGE. Contact a qualified installer or service agency to replace a flooded water heater. Do not attempt to repair the unit! It must be replaced! At least once a year a visual inspection should be made of the main burner and the hot surface igniter assembly for proper flame characteristics and ignition sequences.

  • Page 32: Temperature-Pressure Relief Valve Test

    teMperature-pressure relIef valve test DANGER • Burn hazard. • Hot water discharge. • Keep clear of Temperature- Pressure Relief Valve discharge outlet. It is recommended that the Temperature-Pressure Relief Valve should be checked to ensure that it is in operating condition every 6 months. When checking the Temperature-Pressure Relief Valve operation, make sure that (1) no one is in front of or around the outlet of the Temperature- Pressure Relief Valve discharge line, and (2) that water discharge will...

  • Page 33: Periodic Maintenance

    servIce If a condition persists or you are uncertain about the operation of the water heater contact a service agency. Use this guide to check a “Leaking” water heater. Many suspected “Leakers” are not leaking tanks. Often the source of the water can be found and corrected. If you are not thoroughly familiar with gas codes, your water heater, and safety practices, contact your gas supplier or qualified installer to check the water heater. Read this manual first. Then before checking the water heater make sure the gas supply has been turned “OFF”, and never turn the gas “ON” before the tank is completely full of water.

  • Page 34: Repair Parts List

    Key no. part description outer door anode control valve assembly Plastic Top Blower assembly switch and harness assembly t&p valve drain valve wiring harness anode outlet vent pipe assembly #1 vent pipe assembly #2 vent pipe assembly #3 Inlet Tube pipe nipple Burner tube assembly hot surface Igniter...

  • Page 35: Troubleshooting Guidelines

    trouBleshootInG GuIdelInes Please check guidelines below. For your safety, water heater service should be performed only by a qualified service technician. Read the GENERAL SAFETY INFORMATION section first. INTELLI-VENT TROUBLESHOOTING CHART - USER CONTROL led status The gas control valve/thermostat has sensed inadequate or no earth ground. The gas control valve/thermostat has sensed reversed polarity in the 120 VAC power supply. Pressure switch circuit remaining closed for more than 5 seconds after heating cycle begins.
  • Page 36 led status proBleM 1 Turn the power off for 10-20 seconds then on again to Self diagnostic check has detected a problem with the gas valve driver circuit, internal microprocessor, or 2 If any of these error codes persist or cannot be cleared other internal circuits.
  • Page 37 trouBleshootInG GuIdelInes trouBleshootInG GuIdelInes These guidelines should be utilized by a qualified service agent.

  • Page 38: Notes

    trouBleshootInG GuIdelInes notes...

  • Page 39: Limited Warranty

    lIMIted resIdentIal Gas warrantY THIS WARRANTY IS APPLICABLE TO THE ORIGINAL OWNER ONLY. If the glass lined tank in this water heater shall prove upon examination by (the warrantor) to have leaked during the warranty period in normal residential use, due to natural corrosion from potable water therein, the warrantor will furnish the ORIGINAL OWNER a replacement water heater of equivalent size and current model, or a replacement part for any component part which fails in normal use, in accordance with the warranty terms and conditions...
  • Page 40 500 Tennessee Waltz Parkway Ashland City, TN 37015 Technical Support 800-365-0024 Parts 800-821-2017 Copyright © 2010 State Industries, Inc. All rights reserved.

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