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- Page 1 Service Handbook Residential FVIR Gas Water Heaters MODELS: GSN, GTN, GSL, GTL- Series 200/201 LOW LEAD CONTENT THIS SERVICE HANDBOOK IS FOR USE BY QUALIFIED SERVICE PROFESSIONALS ONLY. 100324808 2000580428 (Rev. A) October 2019...
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Page 2: Table Of Contents
CONTENTS GENERAL SAFETY ..............................3 Tools Required (for servicing gas models): ....................3 TROUBLESHOOTING QUICK REFERENCE ......................5 BASIC INSTALLATION & OPERATION ........................7 Normal Operation ............................9 Combustion Air Requirements: ........................12 DRAINING AND FILLING THE WATER HEATER ....................16 Draining the Water Heater .........................16 Filling the Water Heater ..........................16 CHECKING THE GAS SUPPLY PRESSURE......................17 Checking the Gas Supply Pressure ......................17 CHECKING FOR SUFFICIENT COMBUSTION AIR OR VENTING ISSUES ............17... -
Page 3: General Safety
GENERAL SAFETY 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. - 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. NO HOT WATER: Insufficient Combustion Air or Venting Follow the steps on pp 16 –... - Page 6 WATER LEAKAGE: Thermostat does not shut-off Check the Gas Control Valve/Thermostat as described on p. 18-19. Drain valve dripping/leaking Back flush to clean- out sediment, replace if necessary Tank Leak Check Leakage Checkpoints described on p. 23.
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Page 7: Basic Installation & Operation
BASIC INSTALLATION & OPERATION INSTALLATION OF RESIDENTIAL GAS WATER HEATER Water Supply- Cold* Water Exhaust Vent to Shut-Off Ouside of Building See Labels and Valve Installation Instructions *Massachusett: Install and Use & Care Guide a vacuum relief in cold Union for clearances. - Page 8 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 configurations available. Both valves have similar control elements such as the Gas Control Knob &...
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Page 9: Normal Operation
BASIC INSTALLATION & OPERATION Burner/Manifold Door Assembly: The burner/manifold assembly consists of several components such as: main burner, burner orifice, manifold tube, pilot burner, pilot orifice, pilot tube, igniter, and thermocouple. See the figure below for the complete list of components. The pilot burner remains on once it is manually lit. - Page 10 BASIC INSTALLATION & OPERATION Energy Cut Off (ECO): A metal tube (Temperature Figure 5 Gas Control Knob Probe) mounted onto the back of the gas control valve/thermostat is immersed inside the tank water. Reset Button 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 flow through the...
- Page 11 BASIC INSTALLATION & OPERATION Thermostat Operation: Standard residential water hot water in the upper part of the tank will probably heaters use mechanical thermostats. With a mechanical be very near the “shut off” temperature of the control thermostat, a dial setting of 120° F may shut the burner while incoming cold water drops the water temperature down at a tank temperature between 110°...
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Page 12: Combustion Air Requirements
BASIC INSTALLATION & OPERATION Combustion Air Requirements: Table 1: Minimum Square Typical Room WARNING BTUH Input Feet with with 8’ Ceiling 8’ Ceiling 30,000 9 x 21 Carbon Monoxide Warning 45,000 14 x 20 Water heater must be vented to outdoors. 60,000 15 x 25 75,000... - Page 13 BASIC INSTALLATION & OPERATION All Air from Inside the Building: When additional air Minimum Free Area of Permanent Openings for is to be provided to the confined area from additional Ventilation and Combustion Air Supply - All Air from room(s) within the building, the total volume of the Outdoors Only.
- Page 14 BASIC INSTALLATION & OPERATION Vent Connectors: 1 SQ. INCH PER 1. Type B, Double wall, U.L. Listed Vent Pipe. 2000 BTUH 100 SQ. INCH MINIMUM (EACH) 2. Single wall Vent Pipe. Maintain the manufacturer’s specified minimum clearance from combustible materials when using type B OUTLET CONFINED double wall vent pipe.
- Page 15 • To aid in removing the connector, a thimble or slip joint The following figures are examples of vent pipe system may be used. installations and may or may not be typical for your specific application. Consult the “National Fuel Gas •...
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Page 16: Draining And Filling The Water Heater
DRAINING AND FILLING THE WATER HEATER IMPORTANT: Condensation may occur when the cold Draining the Water Heater tank is first heated and should not be confused with a tank leak. The water heater should be drained if being shut down during freezing temperatures. -
Page 17: Checking The Gas Supply Pressure
CHECKING THE GAS SUPPLY PRESSURE Checking the Gas Supply Pressure Gas pressure checks are done with flowing gas using GAS PRESSURE LABEL WHITE RODGERS GAS CONTROL a gas pressure gauge capable of reading pressure in VALVE/THERMOSTAT SHOWN inches of water column. PRESSURE GAUGE •... -
Page 18: Draft Test
Draft Test External Inspection & Cleaning of the Base-Ring Filter After successfully lighting the water heater, allow the unit to operate for 15 minutes and check the draft hood relief 1. At least annually check the base-ring filter for any opening for proper draft. -
Page 19: 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 20: Replacing The Thermocouple And Gas Control Valve/Thermostat
REPLACING THE THERMOCOUPLE AND GAS CONTROL VALVE/THERMOSTAT Removing the Manifold/Burner Assembly Removing the Burner from the Manifold/Burner Turn off the gas supply to the water heater at the Assembly manual gas shut-off valve. This valve is typically Natural Gas (Low Nox) & L.P. Gas Burner located beside the water heater. -
Page 21: Replacing The Manifold/Burner Assembly
start the thermocouple nut and turn it all the way in by Replacing the Manifold/Burner Assembly hand. An additional quarter turn with a 3/8” open-end wrench will then be sufficient to seat the lockwasher. When you are finished, connect the two wire leads WARNING that go to the thermal switch. -
Page 22: Replacing The Gas Valve
White-Rodgers® gas control valve/thermostat the Replacing the Gas Valve: knob stop must first be depressed before turning the 1. To replace the gas control valve/thermostat, gas control knob. See Lighting Instructions on the reassemble in reverse order. When replacing the gas water heater. -
Page 23: Adjusting The Temperature On The Gas Control Valve Thermostat
ADJUSTING THE TEMPERATURE ON THE GAS CONTROL VALVE THERMOSTAT scald injury. The index bar (Robsertshaw) and mark Water temperature over 125°F (52°C) (White-Rodgers®) are indicative of approximately 120°F can cause servere burns instantly (49°C) and are the preferred starting points, see the resulting in severe injury or death. -
Page 24: Gas Water Heater Sizing Guide
GAS WATER HEATER SIZING GUIDE Use the following information as a guide to approximate washer. the correct size water heater for the residence: • When a whirlpool tub is part of the home • 30 gallon size (21 gallon draw) for one bath equipment, it is suggested that the water heater residence. - Page 25 TECHNICAL BULLETINS WATER HAMMER ..............................26 MINERAL BUILD-UP .............................27 ALUMINUM HYDROXIDE ............................28 CONDENSATION ..............................29 DISCOLORED WATER ............................30 SMELLY WATER ..............................31 CHLORINATION PROCEDURE ..........................32 NOT ENOUGH HOT WATER - GAS ........................33 THERMAL EXPANSION ............................34 LEAKING TEMPERATURE AND PRESSURE RELIEF VALVE ................36 INSULATION BLANKETS .............................37...
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Page 26: Water Hammer
BULLETIN 11 WATER HAMMER GENERAL Water hammer is the destructive force, pounding noise and vibration in a piping system when water flowing 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. The shock wave will then surge back and forth between the point of relief and the point of stoppage until the destructive energy is dissipated in the piping system. -
Page 27: Mineral Build-Up
BULLETIN 13 MINERAL BUILD-UP SYMPTOMS • Rumbling • Crackling • Popping 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 28: Aluminum Hydroxide
BULLETIN 14 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 29: Condensation
BULLETIN 15 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 flue gases condense and how you can differentiate between condensation and leaking. -
Page 30: Discolored Water
BULLETIN 21 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 significant enough to allow water to contact enough bare metal to discolor the contents of even a small tank. -
Page 31: Smelly Water
BULLETIN 22 SMELLY WATER CAUSES The most common cause of “smelly water” is a non-toxic sulfate reducing bacteria, scientifically 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 sulfide(H2S) gas you smell in the water. -
Page 32: Chlorination Procedure
BULLETIN 23 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 33: Not Enough Hot Water - Gas
BULLETIN 35 NOT ENOUGH HOT WATER - GAS CAUSES Complaints regarding an insufficient 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 sufficient hot water may also be exceeded if additional people and/ or appliances are added to the residence. -
Page 34: Thermal Expansion
BULLETIN 45 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 35 THERMAL EXPANSION THE FIX The ideal fix 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. The PRV also offers the benefit of saving water and prolonging the life of water flow valves.
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Page 36: Leaking Temperature And Pressure Relief Valve
BULLETIN 52 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 37: Insulation Blankets
BULLETIN 60 INSULATION BLANKETS 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 38: General Information
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 39 GENERAL INFORMATION One pound of Propane gas contains about 21,600 BTU of heat. 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...
- Page 40 ALL TECHNICAL AND WARRANTY QUESTIONS SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS PURCHASED. IF YOU ARE UNSUCCESSFUL, CONTACT LOCHINVAR TECHNICAL ASSISTANCE AT 1-800-722-2101 OR WWW. LOCHINVAR.COM.
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