Operational Problems - State Water Heaters 301 Series Instruction Manual

OPERATIONAL PROBLEMS

Read and understand this instruction
manual and the safety messages
herein before installing, operating or
servicing this water heater.
Failure to follow these instructions and
safety messages could result in death
or serious injury.
This manual must remain with the
water heater.
This section of the manual is intended to be an aid in correcting
common operational problems, it is not all inclusive. The installer
may be able to observe and correct certain problems which might
arise when the water heater is first put into operation or when it
is re-fired after a prolonged shutdown. However, only qualified
service agents, as defined in Qualifications on page 6,
using appropriate test equipment, should perform any service
procedures on the water heater.
Note: Call the technical support phone number listed on
the back cover of this manual for further technical
assistance or to locate a qualified service agent in
your area.
INSTALLATION ERRORS
Operational problems on new installations are often the result
of installation requirements that have been overlooked rather
than failed components. IE: A "Low Gas Pressure" fault condition
is most often caused by low supply gas pressure rather than a
defective Low Gas Pressure switch. Rough starting and rough
operation are often caused by undersized supply gas lines and/or
the absence of a supply gas regulator at the water heater.
Prior to performing any operational checks inspect the water heater
installation to ensure all installation requirements and instructions
have been maintained and followed. See the
(page 57).
Note: Costs to correct installation errors are not covered
under the limited warranty. See
Heater Limited Warranty
ROUGH STARTING, ROUGH OPERATION
Fire and Explosion Hazard
Do not use water heater with any gas
other than the gas shown on the rating
label.
Excessive gas pressure to gas valve can
cause serious injury or death.
Turn off gas lines during installation.
Contact a qualified installer or service
agency for installation and service.
• Undersized supply gas line (low volume of supply gas) -
see (page 13).
Gas Supply Systems
• Supply gas regulator is not installed per installation
requirements (erratic gas supply volume/pressures) - see
(page 13).
Supply Gas Regulator
• Excessive supply gas pressure - see
and (page 53).
Initial Start Up
• Vent (exhaust) gas recirculation at the vent and intake air
pipe terminations on
Direct Vent Installation
(page 24).
Installation
Installation Checklist
Commercial Water
(page 76).
(page 11)
Table 4
- see
Direct Vent
• Excessive equivalent lengths of intake air and/or vent
(exhaust) piping installed - see
22).
• Debris clogging/blocking the intake air screen(s) - see
(page 24) and
Figure 18
• Debris clogging/blocking the Main Burner - see
(page 7).
MOMENTARY IGNITION
CAUTION
Burn Hazard
•
The combustion chamber and burner sleeve
and housing become very hot during operation.
•
Do not reach into the burner housing or
combustion chamber if the water heater
is still hot.
•
Allow the water heater to cool and always use
gloves when handling the main burner.
If the Main Burner ignites momentarily but does not sustain ignition,
allow the water heater to try to ignite up to two more times until
control system locks out and the Ignition Failure Fault message
is displayed on the control system's LCD. If the water heater is
experiencing rough starts - see
(page 59). For momentary ignition problems without rough
starting check the following:
• Undersized supply gas line (low volume of supply gas) -
see
Gas Supply Systems
• Supply gas regulator is not installed per installation
requirements (erratic gas supply volume/pressures) - see
(page 13).
Supply Gas Regulator
• See the list of possible causes and things to check and
repair for the Ignition Failure Fault message in
(page 61).
Alert Messages
• Debris clogging/blocking the intake air screen(s) - see
(page 24) and
Figure 18
• Debris clogging/blocking the Main Burner - see
(page 7).
NOT ENOUGH OR NO HOT WATER
• No power to the water heater, check breaker and fuses.
• Enable/Disable switch in "Disabled" position. Set to Enable
to allow unit to operate.
• Hot water supply valve(s) to fixtures closed.
• Operating Set Point is set too low, Differential setting is set
too high. See
Control System Operation
• Tank Probe Offset is causing the heating cycles to
terminate prematurely - see
48).
• Ensure there is not any external supervisory control (using
the enable/disable circuit) disabling heating operation.
• The heating capacity of the water heater has been
exceeded, the water heater is unable to meet demand.
• Colder incoming water temperature lengthening the time
required to heat water to desired temperature.
• Hot water piping leaks, open faucets, water heater drain
valve leaking or open.
• Sediment or lime scale accumulation may be affecting
water heater operation. See Maintenance on page 63
for sediment and lime scale removal procedures.
• Water heater not firing at full input rating. Check actual
firing rate of the water heater, see instructions in
(page 56).
The Firing Rate
Note: The water heaters covered by this manual are
capable of modulating their firing rate. The firing
rate is dictated by the hot water draw and various
other temperature limitations.
59
Venting Requirements
(page 27).
Figure 25
Figure 2
Rough Starting, Rough Operation
(page 13).
Fault and
(page 27).
Figure 25
Figure 2
(page 45).
Temperatures Menu
Checking
(page
(page