Table of Contents
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service handbook
commercial / residential gas water heaters
for models:
she 50-100 ne, she 50-100 pe
gp650 ytpdt, gp650 htpdt
series 120 & 121
500 Tennessee Waltz Parkway
Ashland City, TN 37015
installation considerations - pre service
checKs - water heater construction -
operation & service - troubleshooting
servicing should only be performed by a Qualified service agent
PRINTED IN THE U.S.A. 0410
318557-000
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Table of Contents
Related Manuals for State Water Heaters 121 Series
Summarization of Contents
Introduction to Water Heater Service
Qualifications for Service Personnel
Describes installer/agency qualifications based on ANSI standards.
Important Service Warnings
Warns unqualified personnel not to perform procedures.
Service Reminders for Technicians
Emphasizes visual inspection of wiring and connectors.
Required Tools for Water Heater Service
Lists necessary tools for installation and service.
Installation Considerations for Gas Water Heaters
Instruction Manual Importance
Importance of having the water heater’s manual.
Understanding Closed Water Systems
Explains closed systems and their implications.
Thermal Expansion in Water Heaters
Discusses water expansion and its effects.
Air Requirements for Combustion and Ventilation
Highlights importance of proper combustion and ventilation air.
Effects of Contaminated Air
Warns about damage from contaminated air.
Venting Requirements and Guidelines
General Venting Information
Covers Category IV appliances and vent configurations.
Maximum Equivalent Vent Pipe Lengths
Details pipe length and elbow limits.
Vent Pipe Size Requirements
Specifies correct pipe sizing for vent/intake.
Maximum Vent Pipe Elbow Requirements
Limits the number of elbows allowed.
Factory Supplied Fittings and Intake Air
Intake Air Connection Details
Explains intake air connection, screen, and hose barb.
Electrical Requirements and Testing
Grounding and Polarity Verification
Stresses correct grounding and polarity for operation.
Power Supply Test Procedures
Describes how to verify power supply grounding and polarity.
Installation Check List for Water Heaters
Critical Installation Checks
Critical installation checks to prevent problems.
Water Heater Features and Components
Front and Back Views of Components
Identifies components on the front and back of the unit.
Top View of Water Heater Components
Labels components visible from the top.
Combustion Blower and Burner Assembly
Shows exploded and assembled views of key parts.
Operation and Service Overview
How the Water Heater Works
Explains the internal function and gas flow.
Combustion Blower Details
Combustion Blower Assembly Description
Details the blower assembly and its connections.
Burner Assembly Description
Burner Assembly Views
Shows side views of the burner assembly.
Burner Adapter Components
Burner Adapter Identification
Illustrates burner adapter connections and components.
Combustion Blower and Burner Removal
Combustion Blower Removal Procedure
Step-by-step guide to remove the combustion blower.
Combustion Blower Installation
Combustion Blower Installation Procedure
Instructions for reinstalling the combustion blower.
Burner Assembly Removal Procedure
Burner Assembly Removal Steps
Steps to remove the burner assembly.
Burner Assembly Installation Procedure
Burner Assembly Reinstallation
Steps to reinstall the burner assembly.
Flame Sensor Operation and Testing
Flame Sensing Operation Principle
Explains how flame sensing works.
Minimum Flame Sensing Current Requirements
Specifies minimum current for flame proving.
Flame Sensing Current Test
Procedure for Flame Sensing Current Test
Details how to measure flame sensing current.
Igniter Function and Testing
Igniter Current Test Procedure
Describes testing igniter current.
Venturi System Explanation
Venturi Function in Gas Mixing
Explains the venturi's role in gas/air mixing.
Gas Valve Voltage Tests
Testing Gas Valve AC and DC Voltages
Outlines tests for 24 VAC and 24 VDC gas valve signals.
Gas Valve Removal Instructions
Procedure for Gas Valve Removal
Step-by-step instructions for removing the gas valve.
Gas Pressure Specifications
Gas Pressure Ratings and Measurement Points
Details pressure ratings and measurement points.
Gas Pressure Testing Procedure
Steps for Gas Pressure Testing
Procedure for testing gas pressures.
Gas Flow Test Illustration
Gas Flow Test Pressure Changes
Illustrates pressure changes during operating states.
Pressure Switches Overview
Pressure Switch Construction and Operation
Explains pressure switch construction and function.
Types and Applications of Pressure Switches
Describes switch types and their actions.
Control System Monitoring of Pressure Switches
Pressure Switch Fault Messages
Shows LCD messages for pressure switch faults.
Sensing Tube Connections for Pressure Switches
Details sensing tube connections for pressure switches.
Pressure Switch Testing Procedures
Continuity Test During Standby
Tests switch continuity when blower is off.
Pressure Switch Operational Tests
Continuity Test During Operation
Tests switch continuity when blower is running.
Pressure Test During Operation
Tests switch activation pressure.
Temperature Probe Information
ECO High Temperature Limit Switch
Explains the ECO limit switch function.
Temperature Sensor Description
Details the thermistor and its resistance.
Temperature Sensor Test Procedure
Procedure to test the temperature sensor.
ECO Continuity Test Procedure
ECO Continuity Test Steps
Tests the ECO switch continuity.
Control System Hardware Overview
Control System Components
Lists main control system components.
UIM (User Interface Module) Details
Details the UIM's components and location.
Central Control Board (CCB) Enclosure
CCB Enclosure with Front Removed
Shows the CCB enclosure with the front cover off.
CCB Cover Removal and Replacement
CCB Cover Removal Procedure
Steps to remove the CCB enclosure cover.
CCB Cover Replacement Procedure
Steps to replace the CCB enclosure cover.
CCB Circuit Board Layout
CCB Circuit Board Connector Layout
Identifies connectors and dipswitches on the CCB.
S1 Dipswitch Detail and Operation
Explains the function of the dipswitch settings.
Changing Ignition Trial Settings
How to adjust ignition trial settings.
CCB Connection Identification
J1 Socket - Transformer Connections
Lists pins and descriptions for J1 socket.
J2 Socket - Combustion Blower Connections
Lists pins and descriptions for J2 socket.
J3 Socket - Power Supply Connections
Lists pins and descriptions for J3 socket.
J4 Connector - Flame Sensor
Identifies J4 connector for flame sensor.
J5 Socket - Igniter Connections
Identifies J5 socket for igniter.
J6 Socket - Gas Valve and Switches
Lists pins for gas valve & switches.
CCB Connection Identification (Continued)
J7 Socket - Temperature Probe/ECO
Lists pins for temp probe/ECO.
J9 Port - Unused Communication Port
Indicates J9 port is unused.
J10 Socket - Unused
Indicates J10 socket is unused.
J11 Port - Unused Communication Port
Indicates J11 port is unused.
J13 Socket - Blower Speed Control
Lists pins for blower speed control.
J15 Socket - Unused
Indicates J15 socket is unused.
J16 Port - UIM Display Communication
Identifies J16 port for UIM display.
Wiring Diagram for Water Heater
Water Heater Wiring Diagram
Shows electrical connections between components.
Control System Operation Guide
Control System Operation Overview
Introduces control system features and navigation.
Control System Features Explained
Lists key features like navigation, iCOMM, diagnostics.
Commercial vs. Residential Model Differences
Commercial and Residential Model Operations
Differences in operation for commercial/residential.
Control System Navigation Instructions
How to navigate the UIM menus.
User Input Buttons Functionality
Explains the function of the UIM buttons.
Understanding the Desktop Screen
Describes the default display screen and its elements.
Status Icons Guide
Interpreting Status Icons on UIM
Explains icons displayed on the UIM screen.
Control System Operating States
Description of Operating States
Details the different operational states of the control system.
Control System Menu Navigation
Lists and describes available control system menus.
Temperature Settings Adjustment
Operating Set Point and Differential Adjustment
How to adjust set point and differential.
Temperature Menu Details
Tank Temperature Monitoring
Non-adjustable sensed temperature.
Tank Probe Offset Calibration
Adjustable setting for probe calibration.
Heater Status Information
Viewing Heater Status
Displays current status of components and switches.
Display Settings Configuration
Configuring Display Settings
Options for temperature units, backlight, and contrast.
Heater Operational Information
Accessing Heater Information
Displays operating time, cycle counts, and software versions.
Current Fault Information
Viewing Current Fault Messages
Shows current fault or alert message.
Fault History Log
Reviewing Fault History
Lists recent fault and alert messages.
Fault Occurrence Tracking
Monitoring Fault Occurrences
Tracks the total count of fault conditions.
Restoring Factory Defaults
Procedure to Restore Factory Defaults
Resets user settings to factory defaults.
Service Contact Information Setup
Entering Service Contact Details
Allows entry of service provider contact details.
Sequence of Operation
Step-by-Step Sequence of Operation
Step-by-step description of the heating cycle.
Sequence of Operation Flow Chart
Visual Flow Chart of Operation Sequence
Visual representation of the heating cycle.
Troubleshooting Common Issues
Troubleshooting Rough Operation
Checks for rough starting or operation issues.
Troubleshooting Not Enough Hot Water
Lists causes for insufficient hot water.
Using Heater Status Menu for Diagnostics
Displays real-time status of components.
Pre-Service Checks for Technicians
Pre-service checks for common issues.
Control System Unresponsiveness
Troubleshooting a Blank UIM (LCD) Display
Troubleshooting for a blank UIM display.
Troubleshooting Inoperable UIM Buttons
Troubleshooting for unresponsive UIM buttons.
Fault Messages: Electrical and Sensor Issues
AC Reversed Fault Message
Addresses reversed power supply polarity.
Temp Probe Open Fault Message
Troubleshoots open temperature probe circuit.
Temp Probe Short Fault Message
Troubleshoots shorted temperature probe circuit.
Fault Messages: Ignition and Flame Detection
Flame Sensor Short Fault Message
Addresses grounded flame sensor issues.
Flame Detect Error Fault Message
Troubleshoots flame detection errors.
Fault Messages: Temperature and Airflow
Energy Cut Out (ECO) Fault Message
Addresses excessive temperature fault.
Fault Messages: Air Intake Restrictions
Blocked Air Intake Fault Message
Troubleshoots restricted combustion air intake.
Fault Messages: Exhaust and Blower Issues
Blocked Exhaust Fault Message
Troubleshoots blocked vent piping.
Blower Prover Failure Fault Message
Addresses blower prover switch faults.
Fault Messages: Blower Prover Switch
Blower Prover Open Fault Message
Troubleshoots open blower prover switch.
Fault Messages: Igniter Performance
Low Igniter Current Fault Message
Addresses insufficient igniter current.
Fault Messages: Ignition Failure
Ignition Failure Fault Message
Troubleshoots failure to ignite burner.
Fault Messages: System Communication
Ignition Failure (Continued)
Continues troubleshooting ignition failure.
Communication Failure Fault Message
Addresses loss of CCB-UIM communication.
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