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Summary of Contents for State Water Heaters GPX
- Page 1 SERVICE HANDBOOK FOR STANDARD RESIDENTIAL FVIR GAS WATER HEATERS MODELS: GPX, GS6, GSX – SERIES 200/201 GS6, GSX (40-Gallon Short) SERIES 202/203 06/09 316876-000...
- Page 3 Your safety and the safety of others is extremely important in the servicing of this water heater. Many safety- related messages and instructions have been provided in this handbook and on your water heater to warn you and others of a potential hazard. Read and obey all safety messages and instructions throughout this handbook. It is very important that the meaning of each safety message is understood by you and others who service this water heater.
- Page 4 Fire or Explosion Harzard Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. Avoid all ignition sources if you smell Natural or LP gas. Do not expose water heater control to excessive gas pressure.
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Page 5: Troubleshooting Quick Reference
TROUBLESHOOTING QUICK REFERENCE IMPORTANT: Before performing any test, check the area around the water heater for any source of a flammable vapor (i.e gasoline, paint thinners, etc.) If any sources are found do not proceed until they are removed. PROBLEM POSSIBLE CAUSE NO HOT WATER: Insuffi... - Page 6 PROBLEM POSSIBLE CAUSE WATER LEAKAGE: Thermostat does not shut-off Drain valve dripping/leaking Tank Leak TEST / CORRECTIVE ACTION Check the Gas Control Valve/Thermostat as described on p. 20-21. Back fl ush to clean- out sediment, replace if necessary Check Leakage Checkpoints described on p.
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Page 7: Table Of Contents
BASIC INSTALLATION ... 8-16 DRAINING AND FILLING THE WATER HEATER ...17 Draining the Water Heater ...17 Filling the Water Heater ...17 CHECKING THE GAS SUPPLY FOR PRESSURE ...18 CHECKING FOR SUFFICIENT COMBUSTION AIR OR VENTING ISSUES ... 18-19 Combustion Air Test ...18 Draft Test ...19 External Inspection &... -
Page 8: Basic Installation
BASIC INSTALLATION & OPERATION INSTALLATION OF RESIDENTIAL GAS WATER HEATER See Labels and Installation Instructions and Use & Care Guide for clearances. Union To Fixtures - Hot Tempered Water To Fixtures Untempered Cold Hot Water Water Inlet Water Outlet Mixing Valve (Set to 120°F) Follow the Mixing Valve Manufacturer’s... - Page 9 BASIC INSTALLATION & OPERATION This portion of this handbook applies to the Operations and Servicing of Residential Gas, Tank Type, Water Heaters, which are vented atmospherically and use a thermocouple as their electrical source. Control: There are two gas control valve/thermostat confi gurations available. Both valves have similar control elements such as the Gas Control Knob &...
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Page 10: Normal Operation
BASIC INSTALLATION & OPERATION Burner/Manifold Door Assembly: The burner/manifold assembly consists of several components such as: main burner, burner orifi ce, manifold tube, pilot burner, pilot orifi ce, pilot tube, igniter, and thermocouple. See the fi gure below for the complete list of components. The pilot burner remains on once it is manually lit. - Page 11 BASIC INSTALLATION & OPERATION Energy Cut Off (ECO): A metal tube (Temperature Probe) mounted onto the back of the gas control valve/thermostat is immersed inside the tank water. The probe acts as a temperature high limit. If water gets excessively hot, an Energy Cut Off (ECO) switch within the probe opens, interrupting the small electrical current to the gas valve, and gas fl...
- Page 12 BASIC INSTALLATION & OPERATION Thermostat Operation: Standard residential water heaters use mechanical thermostats. With a mechanical thermostat, a dial setting of 120° F may shut the burner down at a tank temperature between 110° and 130° F. The heater will consistently shut off at this same temperature. For this same reason, water temperature may drop 15°...
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Page 13: Combustion Air Requirements
BASIC INSTALLATION & OPERATION Combustion Air Requirements: WARNING Carbon Monoxide Warning Water heater must be vented to outdoors. Vent must be installed by a qualified technician using the local and state codes or, in the absence of local and state codes, the National Fuel Gas Code, ANSI Z223.1 (NFPA 54) - current edition, and/or the installation instructions. - Page 14 BASIC INSTALLATION & OPERATION All Air from Inside the Building: When additional air is to be provided to the confi ned area from additional room(s) within the building, the total volume of the room(s) must be of suffi cient size to properly provide the necessary amount of fresh air to the water heater and other gas utilization equipment in the area.
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Page 15: Vent Connectors
BASIC INSTALLATION & OPERATION 1 SQ. INCH PER 2000 BTUH 100 SQ. INCH MINIMUM (EACH) CONFINED SPACE ALL AIR FROM OUTDOORS USING HORIZONTAL DUCTS Figure 11 ALTERNATIVE OPENING LOCATION CONFINED SPACE ALL AIR FROM OUTDOORS - USING A SINGLE PERMANENT OPENING Figure 12 Vent Pipe System: This water heater must be properly vented for the removal of exhaust gases to... - Page 16 BASIC INSTALLATION & OPERATION • The connector must be firmly attached and sealed to prevent it from falling out. • To aid in removing the connector, a thimble or slip joint may be used. • The connector must not extend beyond the inner edge of the chimney as it may restrict the space between it and the opposite wall of the chimney LISTED LINED...
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Page 17: Draining And Filling The Water Heater
DRAINING AND FILLING THE WATER HEATER D raining the Water Heater The water heater should be drained if being shut down during freezing temperatures. Also, periodic draining and cleaning of sediment from the tank may be necessary. 1. Turn off the gas to the water heater at the manual gas shut-off valve. -
Page 18: Checking The Gas Supply For Pressure
CHECKING THE GAS SUPPLY PRESSURE Checking the Gas Supply Pressure Gas pressure checks are done with flowing gas using a gas pressure gauge capable of reading pressure in inches of water column. • Supply gas pressure checks are measured before the gas control valve/thermostat and as close to the water heater as possible. -
Page 19: Draft Test
CHECKING FOR SUFFICIENT COMBUSTION AIR OR VENTING ISSUES Draft Test After successfully lighting the water heater, allow the unit to operate for 15 minutes and check the draft hood relief opening for proper draft. Make sure all other appliances in the area are operating and all doors/windows are closed when performing the draft test. -
Page 20: Testing The Thermocouple And Gas Control Valve/Thermostat
TESTING THE THERMOCOUPLE AND GAS CONTROL VALVE/THERMOSTAT IMPORTANT: Before performing any test, check the area around the water heater for any source of a Flammable Vapor (i.e gasoline, paint thinners, etc.) If any sources are found do not proceed until they are removed. Thermocouple Output Test The following test will check the DC voltage generated by the thermocouple when the pilot light is lit. -
Page 21: Replacing The Thermocouple And Gas Control Valve/Thermostat
REPLACING THE THERMOCOUPLE AND GAS CONTROL VALVE/THERMOSTAT Removing the Manifold/Burner Assembly 1. Turn off the gas supply to the water heater at the manual gas shut-off valve. This valve is typically located beside the water heater. Note the position of the shut-off valve in the open/on position then proceed to turn it off. -
Page 22: Replacing The Manifold/Burner Assembly
REPLACING THE THERMOCOUPLE AND GAS CONTROL VALVE/THERMOSTAT FERRULE NUT THERMOCOUPLE IGNITER WIRE PILOT PILOT BRACKET MANIFOLD TUBE PILOT TUBE MANIFOLD/BURNER DOOR OPENING TWO PIECE WIRE CONNECTOR Figure 25 Replacing the Manifold/Burner Assembly WARNING Explosion Hazard • Tighten both manifold door screws securely. •... -
Page 23: Removing And Replacing The Gas Control Valve/Thermostat
REPLACING THE THERMOCOUPLE AND GAS CONTROL VALVE/THERMOSTAT CLOSE-UP INSIDE VIEW OF THE COMBUSTION CHAMBER. BRACKET MANIFOLD TUBE Figure 27 Removing and Replacing the Gas Control Valve/Thermostat IMPORTANT: This water heater has a resettable thermal switch installed. Do not attempt to disable or modify this feature in any way. -
Page 24: Adjusting The Temperature On The Gas Control Valve/Thermostat
ADJUSTING THE TEMPERATURE ON THE GAS CONTROL VALVE THERMOSTAT Water temperature over 125°F (52°C) can cause servere burns instantly resulting in severe injury or death. Children, the elderly, and the physically or mentally disabled are at highest risk for scald injury. Feel water before bathing or showering. -
Page 25: Gas Water Heater Sizing Guide
GAS WATER HEATER SIZING GUIDE Use the following information as a guide to approximate the correct size water heater for the residence: • 30 gallon size (21 gallon draw) for one bath residence. • 40 gallon size (28 gallon draw) for two bath residence -or one bath with an automatic clothes washer. •... -
Page 26: Technical Service Bulletins
TECHNICAL BULLETINS WATER HAMMER ...27 MINERAL BUILD-UP ...28 ALUMINUM HYDROXIDE ...29 CONDENSATION ...30 DISCOLORED WATER ...31 SMELLY WATER ...32 CHLORINATION PROCEDURE ...33 NOT ENOUGH HOT WATER ...34 THERMAL EXPANSION ... 35-36 LEAKING TEMPERATURE AND PRESSURE RELIEF VALVE ...37 INSULATION BLANKETS ...38... -
Page 27: Water Hammer
GENERAL Water hammer is the destructive force, pounding noise and vibration in a piping system when water fl owing through a pipeline is stopped abruptly. When water hammer occurs, a high intensity pressure wave travels back through the piping system until it reaches a point of some relief. -
Page 28: Mineral Buildup
SYMPTOMS • Rumbling CAUSE With the increase in fuel costs and hot water consumption, deliming has become a necessity of modern maintenance. Lime (CaCO3), is the most notable factor when discussing water hardness. Lime is present in every water system to some degree. Since lime is inversely soluble [the more you heat, the more lime comes out], higher usage, excessive hardness, and increased heating surface can lead to a high incidence of “limed-up”... -
Page 29: Aluminum Hydroxide
SYMPTOMS “Crackling”, “gurgling”, or “popping” noises from new water heaters (installed less than six months). CAUSE In a few isolated parts of the United States where the water supply has a relatively high pH (8+), water conditions will react with the aluminum anode to form excessive amounts of aluminum hydroxide on the anode and in the bottom of the tank. -
Page 30: Condensation
SYMPTOMS The water heater appears to be releasing water while the main burner is on or water is found surrounding the heater shortly after the water heater has been used. This bulletin explains why fl ue gases condense and how you can differentiate between condensation and leaking. -
Page 31: Discolored Water
SYMPTOMS Rusty, brown, black, or yellow water appearing in the hot water. CAUSES Complaints of discolored water are commonly blamed on water heaters and storage tanks, but in fact, it is a rare occurrence for today’s high quality glass lined tanks to have a lining failure signifi... -
Page 32: Smelly Water
CAUSES The most common cause of “smelly water” is a non-toxic sulfate reducing bacteria, scientifi cally termed Divibrio Sulfurcans. This bacteria often enters the water system through construction or a break in ground piping. The bacteria creates the energy it needs to survive by converting sulfate (SO4) to hydrogen sulfi... -
Page 33: Chlorination Procedure
CAUSES The chlorination procedure is used to eliminate various bacteria that accumulate and grow in water heaters. These bacteria often cause odorous or discolored water conditions. PROCEDURE Please read the steps of the chlorination procedure prior to beginning. If you feel uncomfortable performing any of these steps, contact a service person to perform this procedure for you. -
Page 34: Not Enough Hot Water
NOT ENOUGH HOT WATER - GAS CAUSES Complaints regarding an insuffi cient supply of hot water are typically the result of a water heater that cannot meet the demands of the residence (both people and appliances). The demand for suffi cient hot water may also be exceeded if additional people and/or appliances are added to the residence. -
Page 35: Thermal Expansion
SYMPTOMS • Effects are only noticeable after hot water use followed by periods of no water use. • Relief valve drips during any recovery cycle when no hot or cold water is used. • Hot water pipes creak while heater is recovering and all valves are closed. •... -
Page 36: Thermal Expansion
THE FIX The ideal fi x involves the use of a pressure reducing valve if supply pressures are above 60 to 70 psi, and a properly sized expansion tank. The PRV reduces supply pressures to 40 to 60 psi allowing an economically priced and sized expansion tank to be used. -
Page 37: Leaking Temperature And Pressure Relief Valve
LEAKING TEMPERATURE AND PRESSURE RELIEF VALVE SYMPTOMS • Water seeping around the relief valve tank connection • Leakage at the threaded portion of the relief valve connection • Intermittent weeping and/or dribbling from the relief valve • Large volume of hot water sporadically discharged from the relief valve GENERAL The temperature and pressure relief valve (T &... -
Page 38: Insulation Blanket
GENERAL The purpose of an insulation blanket is to reduce the standby heat loss encountered with storage tank heaters. Most modern water heaters have adequate factory installed insulation, the use of an after market insulation blanket is no longer recommended by most experts. While the use of an external insulation blanket will not void the warranty, the water heater manufacturer explicitly disclaims any liability for problems associated with the use of insulation blankets. -
Page 39: General Information
Draw efficiency is the quantity of hot water available to the consumer before the outlet water temperature decreases 25 degrees F. A 40 gallon water heater will typically provide 70% (28 gallons) of this “usable” hot water (60% is the minimum). The burner or elements are allowed to operate during this test. Incoming, cold water mixes the remaining stored water below this 25 degree limitation. - Page 40 One pound of gas pressure is equal to 27.7 inches water column pressure Inches of Water Column X .036091 = PSI Inches of Water Column X .073483 = Inches of Mercury (Hg.) Centimeters = Inches X 2.54 MM (millimeters) =Inches X 25.4 Meters = Inches X .0254 Doubling the diameter of a pipe will increase its flow capacity (approximately) 5.3 times.
- Page 41 NOTES...
- Page 42 NOTES...
- Page 44 ALL TECHNICAL AND WARRANTY QUESTIONS SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS PURCHASED. IF YOU ARE UNSUCCESSFUL, CONTACT STATE WATER HEATERS RESIDENTIAL TECHNICAL ASSISTANCE 1-800-365-0024 OR WWW.STATEWATERHEATERS.COM.
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