Instruction Manual RESIDENTIAL GAS WATER HEATERS POWER VENT/POWER DIRECT VENT GAS MODELS WITH HOT SURFACE IGNITION Ashland City, TN 37015 www.statewaterheaters.com • For Your Safety • AN ODORANT IS ADDED TO THE GAS USED BY THIS WATER HEATER. Thank you for buying this energy efficient water heater. We appreciate your confidence in our products. ALL TECHNICAL AND WARRANTY QUESTIONS: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS PURCHASED.
table of contents Applicators...............................................................................31 Controls and Switches...................................................................33 Blower Prover Switch..............................................................33 Blocked Exhaust Switch..........................................................33 Blocked Intake Switch.............................................................33 On/Off Switch.............................
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 Precautions Hydrogen Gas Flammable DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN UNDER WATER. Immediately call a qualified service agency to inspect the appliance and to make a determination on what steps should be taken next. Explosion Hazard If the unit is exposed to the following, do not operate heater until all corrective steps have been made by a qualified service agency. Flammable hydrogen gases may be present. 1. External fire.
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General Safety Information Fire or Explosion Hazard Fire Hazard Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. For continued protection against risk of fire: Avoid all ignition sources if you smell gas. Do not expose water heater controls to excessive gas pressure. Do not install water heater on carpeted floor. Do not operate water heater if flood damaged. Use only the gas shown on the water heater rating plate.
introduction Detailed installation diagrams are also found in this manual. These diagrams will serve to provide the installer with a reference. It is essential that all venting, water piping, gas piping and wiring be installed as shown. Thank You for purchasing this water heater. Properly installed and maintained, it should give you years of trouble free service.
features and components GET TO KNOW YOUR WATER HEATER - GAS MODELS A Control Assembly B Blocked Inlet Switch C Blocked Outlet Switch D Fan Prover Switch E Blower Assembly F Burner Assembly G Flame Sensor H Hot Surface Igniter I Junction Box J Gas Valve Assembly K Display Board L Top Plastic Enclosure M Display Enclosure ** N Exhaust Elbow Assembly ** O Condensate Tubing P Off/On Switch Q Display Label R Hot Water Outlet T Gas Supply U Main Manual Gas Shutoff Va
installation consideration ROUGH IN DIMENSIONS FIGURE 1A. Rough-In-Dimensions Units A B C D E F Inches 66.75 49.25 22.00 15.75 3.00 8.00 cm 169.5 125.09 55.88 40.00 7.62 20.32 Top/Side Inlet and Outlet: 3/4” NPT Gas Inlet: 1/2” NPT Capacity, Gas and Electrical Characteristics Approximate Capacity Manifold Pressure Electrical Characteristics U.S. Gals. Liters Gas Type “WC kPA Volts/Hz Amperes 50 189 Nat./LP 0” 0” 120/60 <5 Maximum Supply Pressure: 14 inches W.C. (3.
Locating The Water Heater Carefully choose a location for the new water heater. 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. CAUTION Property Damage Hazard • All water heaters eventually leak. • Do not install without adequate drainage. Whether replacing an existing water heater or installing the water heater in a new location observe the following critical points: 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. • Do not apply insulation to the top of the water heater, as this will interfere with safe operation of the blower assembly. • Do not cover the outer door, thermostat or temperature & pressure relief valve. • Do not cover the instruction manual. Keep it on the side of the water heater or nearby for future reference.
Outdoor Air Through Two Openings ventilation systems, clothes dryers and fireplaces shall also be considered in determining the adequacy of a space to provide combustion, ventilation and dilution air. Unusually Tight Construction In unconfined spaces in buildings, infiltration may be adequate to provide air for combustion, ventilation and dilution of flue gases. However, in buildings of unusually tight construction (for example, weather stripping, heavily insulated, caulked, vapor barrier, etc.
Air From Other Indoor Spaces 1. 1 square inch per 3000 Btu/hr (700 mm2 per kW) of the total input rating of all appliances located in the enclosure, and 2. Not less than the sum of the areas of all vent connectors in the space. Outdoor Air Through Two Horizontal Ducts FIGURE 7. FIGURE 6. The confined space shall be provided with two permanent openings, one commencing within 12 inches (300 mm) of the top and one commencing within 12 inches (300 mm) of the bottom of the enclosure. See Figure 7.
installing the new water heater CHEMICAL VAPOR CORROSION 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. Spray can propellants, cleaning solvents, refrigerator and air conditioning refrigerants, swimming pool chemicals, calcium and sodium chloride (water softener salt), waxes, and process chemicals are typical compounds which are potentially corrosive.
Mixing Valves Water temperature over 125°F (52°C) can cause severe burns instantly resulting in severe injury or death. in improperly sanitized dishes. Where pressures are high, a water pressure reducing or flow regulating control valve should be used in the line to the dishwashing machine and should be adjusted to deliver water pressure between these limits. HOT WATER OUTLET Children, the elderly and the physically or mentally disabled are at highest risk for scald injury.
Figure 9. CLOSED WATER SYSTEMS Figure 10. Water supply systems may, because of code requirements or such conditions as high line pressure, among others, have installed devices such as pressure reducing valves, check valves, and back flow preventers. Devices such as these cause the water system to be a closed system.
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. To prevent bodily injury, hazard to life, or property damage, the relief valve must be allowed to discharge water in adequate quantities should circumstances demand. If the discharge pipe is not connected to a drain or other suitable means, the water flow may cause property damage.
gas piping Consideration must be given to avoid freezing of the condensate lines which could result in excessive build up of condensate inside the water heater. Waterproof heat tape may be required to prevent freezing of the condensate lines. Please ensure that the outlet of the condensate drain does not create a slippery condition which could lead to personal injury. Make sure gas supplied is same type listed on model rating plate. The inlet gas pressure must not exceed 14 inch water column (3.
HIGH ALTITUDE INSTALLATIONS SEDIMENT TRAPS A sediment trap shall be installed as close to the gas inlet of the water heater as practical at the time of water heater installation. The sediment trap shall be either a tee fitting with a capped nipple in the bottom outlet or other device recognized as an effective sediment trap. This high efficiency water heater is certified for use without modification for an altitude of 10,000 feet (3,079 meters).
VENTING planned location of the vent terminal. 1. Layout total vent system to use a minimum of vent pipe and elbows. 2. This water heater is capable of venting flue gases equivalent to 45’ (13.7 m) of 2” pipe, 128’ (39 m) of 3” pipe as listed in Table 2. Table 2 Number of 90° Elbows 1 2 3 4 5 6 2” Maximum Pipe - ft. (m) 40 (12.19) 35 (10.66) 30 (9.14) 25 (7.62) 20 (6.09) 15 (4.57) 3” Maximum Pipe - ft. (m) 120 (36.57) 115 (35.05) 110 (33.52) 105 (32) 100 (30.48) 95 (28.
PVC Materials should use ASTM D-2564 Grade Cement; CPVC Materials should use ASTM F-493 Grade Cement and ABS Materials should use ASTM D-2235 Grade Cement. If you are installing your system so that it vents through roof, please refer to section titled INSTALLATION OF VERTICAL VENT SYSTEM. If the water heater is being installed as a replacement for an existing power vented heater in pre-existing venting, a thorough inspection of existing venting system must be performed prior to any installation work.
Installation Requirements - Commonwealth of Massachusetts Commonwealth of Massachusetts observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a) 1 through 4.
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 B B C OPERABLE V OPERABLE V B B FI XE D CLOSED V M X V X V K J A B V VENT TERMINAL X AIR SUPPLY INLET AREA WHERE TERMINAL IS NOT PERMITTED Figure 13 Vent terminal clearances for “Power Vent” installations. Power Vent configurations use room air for combustion.
Termination Clearances Sidewall Direct Vent DIRECT VENT (using outdoor 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 OPERABLE V B B C B FI XE D CLOSED M X V B V X V K J A B V VENT TERMINAL X AIR SUPPLY INLET AREA WHERE TERMINAL IS NOT PERMITTED Figure 14 Vent terminal clearances for “Direct Vent” installations. Direct Vent configurations use outdoor air for combustion.
SEQUENCE OF INSTALLATIONS, FIGURE 15A INSTALLATION SEQUENCE Cut a length of PVC pipe about 3.5 inches (8.9 cm) longer than the wall thickness at the opening. Glue the vent terminal to this section of pipe. Slide the wall plate over the pipe to stop against the vent terminal. Place a 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.
VERTICAL VENT TERMINAL INSTALLATION WHEN TERMINATING THROUGH A ROOF, THE FOLLOWING SPECIFICATIONS PERTAINING TO TERMINAL LOCATION MUST BE FOLLOWED. 1. Proper support must be provided for all pipe protruding through the roof. 2. The vertical roof terminations should be sealed with a plumbing roof boot or equivalent flashing. 3. The intake vent termination and the exhaust vent termination must penetrate the same side of roof. 4.
Concentric vent installation 1. Determine best location for termination kit. This appliance is certified for concentric venting with concentric vent kit #9003910105 and #9006328005. Follow instructions below for proper installations. NOTE: Roof termination is preferred since it is less susceptible to damage, has reduced chances to intake contaminants, and less visible vent vapors. KIT COMPONENTS 2. Cut 1 hole (5 in. diameter) Each kit is comprised of the following: 3.
5. Secure assembly to roof structure as shown in Figure 23 using field supplied metal strapping or equivalent support material. NOTE: Ensure termination height is above the roof surface or anticipated snow level as shown in Figure 23. 6. Install rain c ap and small diameter pipe assembly in r o o f p e n e t r a t i o n a s s e m b l y, E n s u r e s m a l l d i a m e t e r pipe is cemented and bottomed in Y concentric fitting. 7.
MULTI-CONCENTRIC VENT TERMINATIONS 5. Install rain cap and small diameter pipe assembly in Y concentric fitting and large pipe assembly. Ensure small diameter pipe is bottomed and cemented in Y concentric fitting. When two or more appliances are direct vented with concentric vent terminations near each other, each appliance must be individually vented. NEVER common vent this appliance.
direct vent diagram 12” MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL 12” MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL Figure 29. Figure 28. 24” MINIMUM SEPARATION. EXHAUST MUST BE AT SAME LEVEL OR ABOVE INTAKE TERMINAL. Figure 30. Figure 31. When direct venting through the wall, as shown in Figure 32, the exhaust should terminate a minimum of 24” from the air intake. The exhaust may be rotated up to 45 degrees left or right as long as the 24” distance is maintained.
VENT PIPE PREPARATION PRIMER 1. INITIAL PREPARATION. 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. 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 B C.
CONTROLS AND SWITCHES pressure to change the electrical contacts from normally closed to open. When this switch prevents the unit from igniting, most likely the exhaust is blocked by some means. Check to see if the condensate is allowed to flow freely from the exhaust elbow and for obstructions in the exhaust venting and exhaust vent terminal. Also verify that the vent length does not exceed the maximum allowed as shown in the Vent Section of this manual.
CAUTION LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION. VERIFY PROPER OPERATION AFTER SERVICING. THIS WATER HEATER IS POLARITY SENSITVE. B EFO R E A PPLYI N G ELECTRICITY TO THIS HEATER BE CERTAIN THAT SUPPLY NEUTRAL WIRE TO GROUND CHECK INDICATES ZERO VOLTAGE. POWER VENT WIRING SCHEMATIC - Figure 34.
FOR YOUR SAFETY READ BEFORE LIGHTING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. BEFORE OPERATING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES. A. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do NOT try to light the burner by hand. B. BEFORE OPERATING smell all around the appliance area for gas.
temperature regulation 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 temperatures be set for the lowest temperature which satisfies your hot water needs. This will also provide the most energy efficient operation of the water heater. for the lowest temperature which satisfies your hot water needs. This will also provide the most energy efficient operation of the water heater and minimize scale formation.
control system operation Overview User Input Buttons The water heaters covered in this manual are equipped with an electronic control system that regulates water temperature inside the storage tank. Heating cycles and ignition are managed by the control system. The ECO (energy cut out), Flame Sensor, pressure switches and Temperature Probe is monitored by the control system. The Combustion Blower, Igniter and the 24 Volt Gas Valve are all energized by the control system.
Status Icons The Status Icons are displayed on the Desktop screen and convey operational and diagnostic information. The icons are described in the table below. Table 3. Icon Description Water temperature in the tank has fallen. Shaded area of the animated thermometer icon will rise and fall in response to water temperature in the storage tank as sensed from the Temperature Probe. Water temperature in the tank has reached the Operating Set Point. The control system enters the Standby mode.
Operating States The current operational state of the water heater is displayed on the Desktop screen as the "Status." The common operational states are described in the table below. Table 4. State Description Standby The water heater is not in an active heating cycle. IE: the Tank Temperature is at or above the Operating Set Point. Input Verification The control system is conducting a diagnostic check at the beginning of a heating cycle.
User Settings & Control System Menus Temperatures Operating Set Point And Differential Adjustment The Operating Set Point is adjustable from 90°F (42°C) to 180°F (82°C) for commercial and 160°F (71°C) on residential models. The factory setting is 120°F (49°C). The Differential is adjustable from 2° to 20°. The factory setting is 8°. These user settings are accessed from the Temperatures menu. These instructions explain how to adjust these settings and navigate the control system.
Temperatures (cont) Description/Action Display • Tank Temperature - non adjustable - control system sensed temperature from the Temperature Probe. • Tank Probe Offset - adjustable user setting, range -5° to +5° (factory setting 0°). The Tank Probe Offset is used to calibrate control system temperature sensing. This can improve the precision of temperature control in the storage tank and at points of use.
Display Settings Description/Action Display Select Display Settings from the Main Menu and press the Operational Button under "SELECT" to enter this menu. This menu contains adjustable display options for viewing information on the LCD screen. Use the Up & Down Buttons to navigate the menu. Display Settings • Temperature Units - Adjustable user setting that changes temperature units display to Celsius °C or Fahrenheit °F.
Current Fault Description/Action Display Select Current Fault from the Main Menu and press the Operational Button under "SELECT" to enter this menu. This menu contains non adjustable operational information. Use the Up & Down Buttons to navigate the menu. Blocked Exhaust Fault occurred 2 mins ago The exhaust is blocked or restricted. Ensure condensate hose is draining. This menu contains the current Fault or Alert error message. The time the Fault or Alert message occurred appears directly below.
Service Contact Information The control system has a discrete menu that Installing contractors and/or service agents can access to enter contact information for their customers. This contact information will be displayed with all Fault and Alert messages. Description/Action Display From the Desktop Screen press and hold down the middle (unmarked) Operational Button for 30 seconds and then release it.
for your information START UP CONDITIONS common complaint associated with the anode rod is one of a “rotten egg smell” in the hot water. The smell is a result of four factors which must all be present for the odor to develop: 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. a. A concentration of sulfate in the supply water. b.
periodic maintenance Venting System Inspection rate of anode rod depletion. Once the anode rod is depleted, the tank will start to corrode, eventually developing a leak. Certain water conditions will cause a reaction between the anode rod and the water. The most common complaint associated with the anode rod is a “rotten egg smell” produced from the presence of hydrogen sulfide gas dissolved in the water. IMPORTANT: Do not remove this rod permanently as it will void any warranties.
5. Close the cold water inlet valve to the water heater. 6. Connect a hose to the water heater drain valve and terminate it to an adequate drain. 7. Open the water heater drain valve and allow all the water to drain from the storage tank. 8. Close the water heater drain valve when all water in the storage tank has drained. Figure 36. 9. Close the hot water faucet opened in Step 4.
maintenance Temperature-Pressure Relief Valve Test If the Temperature-Pressure Relief Valve on the water heater weeps or discharges periodically, this may be due to thermal expansion. Burn hazard. Note: Excessive water pressure is the most common cause of Temperature-Pressure Relief Valve leakage. Excessive water system pressure is most often caused by “thermal expansion” in a “closed system.” See Closed Water Systems and Thermal Expansion on pages 15 and 16.
leakage checkpoints Never use this water heater unless it is completely filled with 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. A *Condensation may be seen on pipes in humid weather or pipe connections may be leaking. B. *The anode rod fitting may be leaking. C. Small amounts of water from temperature-pressure relief valve may be due to thermal expansion or high water pressure in your area.
troubleshooting Installation Checklist Flow Chart. The list below represents some of the most critical installation requirements that, when overlooked, often result in operational problems, down time and needless parts replacement. This is not a complete list. Before performing any troubleshooting procedures use the list below to check for installation errors. Costs to correct installation errors are not covered under the limited warranty.
Sequence Of Operation Flow Chart If tank temperature drops below Operating Set Point minus Differential setting a heating cycle is activated Control System performs diagnostic checks Normal State of all pressure switches and ECO are checked Blower Prover pressure switch verified open All other pressure switches and ECO are verified closed NO Control System Locks Out Displays Fault Msg Combustion Blower is energized Pre-Purge cycle Blower Prover switch contacts confirmed closed by control system NO Co
Operational Problems 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 Rough Starting, Rough Operation on this page.
Note: If you are not qualified and licensed or certified as required by the authority having jurisdiction to perform a given task do not attempt to perform any of the diagnostic or service procedures described in the following section. mark. The water heater will continue to operate during an Alert condition but the water heater must be serviced by a qualified service agent as soon as possible.
Fault And Alert Messages Call the technical support phone number listed on the back cover for further technical assistance or to locate a qualified service agent in your area. Possible Causes - Check/Repair Displayed Fault/Alert Message • The water heater’s control system is polarity sensitive and will lock out and disable heating operation if the polarity of the power supply is reversed. The control system will display the “AC Reversed” Fault message on the LCD in this condition.
Fault And Alert Messages (cont) Call the technical support phone number listed on the back cover for further technical assistance or to locate a qualified service agent in your area. Possible Causes - Check/Repair Displayed Fault/Alert Message • The control system has detected the Blower Prover Switch contacts are closed when they should be open at the beginning of a heating cycle. • Pinched/shorted Blower Prover Switch wiring. • Jumper wire connected to the Blower Prover Switch - remove jumper wire.
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Limited Warranty State Water Heaters, the warrantor, extends the following LIMITED WARRANTY to the owner of this water heater. 1.
500 Tennessee Waltz Parkway, Ashland City, TN 37015 Phone: 800-527-1953 Fax: 800-433-2515 www.statewaterheaters.
