Instruction Manual RESIDENTIAL GAS WATER HEATERS POWER VENTED GAS MODELS W/HOT SURFACE IGNITION NOT FOR USE IN MANUFACTURED (MOBILE) HOMES MODEL GP6 50YIVIT SERIES 100 Technical Support: 800-365-0024 Parts: 800-821-2017 www.statewaterheaters.com Low Lead Content • For Your Safety • AN ODORANT IS ADDED TO THE GAS USED BY THIS WATER HEATER. ALL TECHNICAL AND WARRANTY QUESTIONS: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS PURCHASED.
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. Read and obey all safety messages and instructions throughout this manual.
GENERAL SAFETY INFORMATION 3
GENERAL SAFETY INFORMATION at least 18" (45.7 cm) above the floor.
TABLE OF CONTENTS SAFE INSTALLATION, USE AND SERVICE................................................ 2 APPROVALS................................................................................................. 2 GENERAL SAFETY INFORMATION..........................................................3-4 TABLE OF CONTENTS................................................................................. 5 INTRODUCTION...........................................................................................
INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS Commonwealth of Massachusetts Inspection 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 the venting, i
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 O Inlet Dip Tube P Temperature & Pressure Relief Valve HH Bushing II Nipple JJ Condensate Tee K K Adapter LL Plug MM Vent Pipe Assembly #1 NN Vent Pipe Assembly #2 OO Vent Pipe Assembly #3 PP Side Recirculation Loop In
TYPICAL INSTALLATION CONDENSATE HOSE AND DRAIN PAN FIGURE 1A.
TYPICAL INSTALLATION MIXING VALVE / THERMAL EXPANSION TANK USAGE AND SPACE HEATING FIGURE 2. heater (see Figure 3) or at hot water taps to further reduce system water temperature. Mixing Valves DANGER Mixing valves are available at plumbing supply stores. Consult a Qualified Installer or Service Agency. Follow mixing valve manufacturer’s instructions for installation of the valves. Water temperature over 125°F (52°C) can cause severe burns instantly resulting in severe injury or death. TABLE 1.
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. This water heater is not for use in manufactured (mobile) homes or outdoor installation. Whether replacing an old water heater or putting the water heater in a new location, the following critical points must be observed: 1.
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. If this water heater will be used in beauty shops, barber shops, cleaning establishments, or self-service laundries with dry cleaning equipment, it is imperative that the water heater or water heaters be installed so that combustion and ventilation air be taken from outside these areas.
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. free area and metal louvers and grilles will have 75% free area. Non motorized louvers and grilles should be fixed in the open position.
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.
INSTALLING THE NEW WATER HEATER CHEMICAL VAPOR CORROSION This water heater should not be connected to any heating systems or component(s) used with a non-potable water heating appliance. 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. All piping components connected to this unit for space heating applications should be suitable for use with potable water.
Thermal Expansion duct tape, electrical tape, or equivalent. IMPORTANT: The insulation and tape must not block the discharge opening or hinder access to the manual relief lever (Figure 11). Ensure a discharge pipe is installed into the T&P valve discharge opening per the instructions in this manual. 4. Locate the hot water (outlet) & cold water (inlet) pipes to the water heater. 5. Locate the slit running the length of a section of pipe insulation. 6.
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. Do not connect discharge piping directly to the drain unless a 6” (15.2 cm) air gap is provided.
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.
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.
Termination Clearances Sidewall Power Vent POWER VENT (using room air for combustion) EXTERIOR CLEARANCES FOR SIDEWALL VENT TERMINATION G V D H A v E L v B FI XE D CLOSED V F OPERABLE V B B C OPERABLE V B B FI XE D CLOSED V M X V J A X V K B V VENT TERMINAL X AIR SUPPLY INLET AREA WHERE TERMINAL IS NOT PERMITTED FIGURE 15. Vent terminal clearances for “Power Vent” installations. Power Vent configurations use room air for combustion.
PLANNING THE VENT SYSTEM of cracks or fractures, particularly at joints between elbows and other fittings and straight runs of vent pipe. Check system for signs of sagging or other stresses in joints as a result of misalignment of any components in system. If any of these conditions are found, they must be corrected in accordance with venting instructions in this manual before completing installation and putting water heater into service.
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.
bead of caulking (not supplied) around the gap between the pipe and cover plate. Apply enough to fill some of the gap between the pipe and wall. Place some of the caulking on the back of the plate to hold it against the wall after installation. If the vent pipe is installed up to the wall, with a coupling on the end against the wall opening, the pipe with the vent terminal can be prepared for gluing before inserting through the wall.
INSTALLATION OF VENT SYSTEM, SIDEWALL additional vent pipe when calculating maximum equivalent feet of venting. 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.
VENT ATTENUATION ASSEMBLY INSTALLATION INSTRUCTIONS 4. Make sure the VAA and vent pipe is supported securely to a permanent fixture (stud or wall). Use standard support straps (not supplied with kit) that may be found at a local hardware store. Failure to properly support the VAA and the surrounding vent pipe could create a hazardous situation. DO NOT puncture any surface of the VAA. The Vent Attenuation Assembly (VAA) is designed to provide a reduction in fan noise created in the blower wheel.
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. 7. Once installed along with the rest of the vent configuration, make sure to operate the unit through at least one heat up cycle to ensure there is no leakage around the hose barb or any joints of the VAA or vent pipe system.
VENT PIPE PREPARATION PRIMER It is recommended that Tetrahydrofuran (THF) be used to prepare the surfaces of pipe and fittings for solvent welding. Do not use water, rags, gasoline or any other substitutes for cleaning PVC or CPVC surfaces. A chemical cleaner such as MEK may be used. 1. INITIAL PREPARATION A. Make sure the solvent cement you are planning to use is designed for the specific application you are attempting. B.
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 E F.
TEMPERATURE REGULATION To avoid any unintentional changes in water temperature settings, the control has a tamper resistant feature for changing the temperature setting. To change the temperature setting follow these instructions: 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.
FOR YOUR INFORMATION START UP CONDITIONS Do not remove the anode leaving the tank unprotected. By doing so, all warranty on the water heater tank is voided. 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.
Burner OPERATION AND Inspection must be maintained. See “Locating the New Water Heater” section. Combustible materials such as clothing, cleaning materials, or flammable liquids, etc. must not be placed against or adjacent to the water heater which can cause a fire. 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.
Temperature-Pressure Relief Valve Test DANGER DRAINING AND FLUSHING It is recommended that the water heater storage tank be drained and flushed every 6 months to reduce sediment buildup. The water heater should be drained if being shut down during freezing temperatures. See Typical Installation section in this manual for location of the water heater components described below. • Burn hazard. • Hot water discharge. • Keep clear of Temperature- DANGER Pressure Relief Valve discharge outlet.
Service the water heater contact a service agency. 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. 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. Read this manual first.
REPAIR PARTS LIST Key No.
TROUBLESHOOTING GUIDELINES TROUBLE SHOOTING 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 PROBLEM SOLUTION 1 The gas control valve/thermostat has sensed inadequate or no earth ground. 2 The gas control valve/thermostat has sensed reversed polarity in the 120 VAC power supply.
# 7 8 9 LED STATUS PROBLEM SOLUTION Self diagnostic check has detected a problem with the gas valve driver circuit, internal microprocessor, or other internal circuits. 10 The gas control valve/thermostat has sensed main burner flame out of proper sequence. 11 Water temperature in the tank has exceeded 195° F and has activated the ECO (energy cut off) high temperature limit. 12 Self diagnostic check has detected that one or both of the temperature adjust buttons are stuck.
TROUBLESHOOTING GUIDELINES These guidelines should be utilized by a qualified service agent.
TROUBLESHOOTING NOTES GUIDELINES 38
lIMIted resIdentIal Gas warrantY b. Shipping and delivery charges for forwarding the new water heater or replacement part from the nearest distributor and returning the claimed defective heater or part to such distributor except in the state of California where such charges are the manufacturer’s responsibility. c. All cost necessary or incidental for handling and administrative charges, and for any materials and/or permits required for installation of the replacement heater or part.
www.statewaterheaters.com 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.