State Water Heaters GP6 50 120 Instruction Manual Download Page 1

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Instruction Manual

PRINTED 0410

317447-000

Keep thIs Manual In the pocKet on heater for future reference

whenever MaIntenance adjustMent or servIce Is requIred.

power vent/power dIrect vent Gas Models

wIth hot surface IGnItIon

all technIcal and warrantY questIons:

SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS

PURCHASED. IF YOU ARE UNSUCCESSFUL, CALL THE TECHNICAL SUPPORT PHONE NUMBER SHOWN ON THE WATER HEATER LABELING.

resIdentIal Gas water heaters

•

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.

Ashland City, TN 37015

www.statewaterheaters.com

Summary of Contents for GP6 50 120

Page 1: ...ARRANTY QUESTIONS SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS PURCHASED IF YOU ARE UNSUCCESSFUL CALL THE TECHNICAL SUPPORT PHONE NUMBER SHOWN ON THE WATER HEATER LABELING RESIDENTIAL GAS WATER HEATERS 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 product...

Page 2: ...sed 25 Vertical Vent Terminal Installation 26 Concentric Vent Installation 27 Kit Components 27 Safety Considerations 27 Installation Procedure 1 Roof Termination see Figure C 27 direct vent diagram 30 Vent Pipe Preparation 31 Primer 31 Primer and Cement 31 Applicators 31 Controls and Switches 33 Blower Prover Switch 33 Blocked Exhaust Switch 33 Blocked Intake Switch 33 On Off Switch 33 Hot Surfac...

Page 3: ... birth defects or other reproductive harm and requires businesses to warn of potential exposure to such substances This product contains a chemical known to the State of California to cause cancer birth defects or other reproductive harm This appliance can cause low level exposure to some of the substances listed in the Act DANGER WARNING CAUTION CAUTION DANGER indicates an imminently hazardous si...

Page 4: ... any electrical appliance connected to the hot water system If hydrogen is present there will probably be an unusual sound such as air escaping through the pipe as the water begins to flow There should be no smoking or open flame near the faucet at the time it is open Read and understand this instruction manual and the safety messages herein before installing operating or servicing this water heat...

Page 5: ...5 general safety information ...

Page 6: ...th NFPA 54 Use joint compound or Teflon tape compatible with propane gas Fire and Explosion Hazard Turn off gas lines during installation Contact a qualified installer or service agency for installation and service Excessive gas pressure to gas valve can cause serious injury or death Do not use water heater with any gas other than the gas shown on the rating plate Turn off power to the water heate...

Page 7: ...arnings and all instructions are essential to the proper operation of the water heater and your safety 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 Particular attention should be given to the installation of thermometers at th...

Page 8: ... Surface Igniter I Junction Box J Gas Valve Assembly K Display Board L Top Plastic Enclosure Z T P Relief Valve AA Rating Plate BB Labels CC Drain Valve DD Vent Terminal EE Drain Pan FF Anode GG Insulation HH Upper Temperature Probe II Access Door REPLACEMENT PARTS AND DELIMING PRODUCTS Replacement parts and recommended delimer may be ordered through authorized servicers or distributors When order...

Page 9: ...essure for Natural Gas 3 50 87kPa Minimum Supply Pressure for Propane Gas 8 00 1 99kPa Minimum pressure must be maintained under both load and no load dynamic and static conditions Recovery Capacities U S Gallons Hr and Liters Hr at Temperature Rise Indicated Input Recovery Capacities Rating Btu hr Rating kW Temp Rise F 30 40 50 60 70 80 90 100 110 120 130 140 C 17 22 28 33 39 44 50 56 61 67 72 78...

Page 10: ...ater where an adequate supply of fresh air for combustion and ventilation can be obtained See Combustion Air and Ventilation on page 11 9 Locate the water heater where the vent and intake air piping when installed will remain within the maximum equivalent lengths allowed See Venting on page 20 10 Do not locate the water heater where noise such as the Combustion Blower during normal operation will ...

Page 11: ...th 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 Do obtain new warning and instruction labels from the manufacturer for placement on the blank...

Page 12: ...w do not take in to account the presence of louvers grilles or screens in the openings The required size of openings for combustion ventilation and dilution air shall be based on the net free area of each opening Where the free area through a design of louver or grille or screen is known it shall be used in calculating the size of opening required to provide the free area specified Where the louve...

Page 13: ...installed in the enclosure When ducts are used they shall be of the same cross sectional area as the free area of the openings to which they connect The minimum dimension of rectangular air ducts shall be not less than 3 inches Air From Other Indoor Spaces FIGURE 7 The confined space shall be provided with two permanent openings one commencing within 12 inches 300 mm of the top and one commencing ...

Page 14: ...utral wires in the 120 VAC power supply are reversed the control system will declare a Fault condition and lock out heating operation will be disabled until the power supply is correctly wired The control system will display the AC Reversed Fault message on the LCD CHEMICAL VAPOR CORROSION CORROSION OF THE FLUEWAYS AND VENT SYSTEM MAY OCCUR IF AIR FOR COMBUSTION CONTAINS CERTAIN CHEMICAL VAPORS SU...

Page 15: ...are designed to operate with water flow pressures between 15 and 25 pounds per square inch 103 kPa and 173 kPa Flow pressures above 25 pounds per square inch 173 kPa or below 15 pounds per square inch 103 kPa will result 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...

Page 16: ...up This condition is not covered under the limited warranty The temperature pressure relief valve is not intended for the constant relief of thermal expansion A properly sized thermal expansion tank should be installed on all closed systems to control the harmful effects of thermal expansion Figure 10 NOTE To protect against untimely corrosion of hot and cold water fittings it is strongly recommen...

Page 17: ... 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 To preven...

Page 18: ...izing filter prior to disposal Caution must be used to ensure that the drain is free and clear of debris and will not allow backflow through the condensate hose 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 en...

Page 19: ...all 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 Contaminants in the gas lines may cause improper operation of the gas control valve that may result in fire or explosion Before attachin...

Page 20: ... above are exclusive of the termination That is the termination with an installed screen is assumed to be in the system and the remainder of the system must not exceed the lengths discussed above 3 The exhaust elbow assembly is designed to accept only straight sections of 2 pipe To start a minimum 2 5 1cm maximum 6 long of 2 pipe must be inserted and glued to the exhaust elbow assembly if utilizin...

Page 21: ...heater to allow drainage of condensation INSTALLATION OF VENT SYSTEM Before beginning installation of piping system thoroughly read the section of this manual VENT PIPE PREPARATION If you are installing your system so that it vents through roof please refer to section titled INSTALLATION OF VERTICAL VENT SYSTEM VENT TERMINAL INSTALLATION SIDEWALL 1 Install the vent terminal by using the cover plat...

Page 22: ... terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size gas vent directly below Keep clear of all obstructions Inspection The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless upon inspection the inspector Installation Requi...

Page 23: ... inlet into building or combustion air inlet to any other appliance 4 feet 1 2 m below or to side of opening 1 foot 30 cm above opening D Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 feet 61 cm from the center line of the terminal 12 inches 30 cm K Clearance to a mechanical air supply inlet 3 feet 91 cm above if within 10 feet 3 m horizontall...

Page 24: ...pply inlet into building or combustion air inlet to any other appliance 6 inches 15 cm for appliances up to 10 000 Btu hr 3 kW 9 inches 23 cm for appliances between 10 000 Btu hr 3 kW and 50 000 Btu hr 15 kW 12 inches 30 cm for appliances above 50 000 Btu hr 15 kW D Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 feet 61 cm from the center line ...

Page 25: ... READ THE VENT PIPE MANUFACTURER S INSTALLATION INSTRUCTIONS 1 After the points of termination have been determined use the cover plates as templates to mark the holes for the vent pipes to be inserted through the wall BEWARE OF CONCEALED WIRING AND PIPING INSIDE OF WALL If the vent terminals are being installed on the outside of a finished wall it may be easier to mark both the inside and outside...

Page 26: ... must be no closer than 24 61cm The specifications are displayed in Figures 17 and 18 NOTE Exhaust vent terminal is installed using the same procedure Flat Roof Installation On flat roof installations the intake air and the vent terminations must be a minimum of 24 inches 60 cm above any parapet vertical wall or structure within 10 feet 3 m horizontally See figure 19 Figure 17 Figure 18 INTAKE AIR...

Page 27: ... cause intermittent operation INSTALLATION PROCEDURE 1 ROOF TERMINATION see Figure 23 1 Determine best location for termination kit NOTE Roof termination is preferred since it is less susceptible to damage has reduced chances to intake contaminants and less visible vent vapors 2 Cut 1 hole 5 in diameter 3 Partially assemble concentric vent termination kit a Cement Y concentric fitting to larger di...

Page 28: ...ants shrubs or air conditioning equipment Termination kit positioned so it will not be affected by wind eddy that may allow recirculation of combustion products or airborne leaves or light snow Termination kit positioned where it will not get damaged or be subjected to foreign objects such as stones balls etc Termination kit positioned where the vent vapors will not be objectionable NOTE See the v...

Page 29: ...ion more than 60 in See Figure 20 Do not use field supplied couplings to extend pipes Airflow restriction will occur and the heater pressure switch may cause intermittent operation 7 Cement heater combustion air and vent pipes to concentric vent termination assembly See Figure 25 for proper pipe attachment 8 Operate heater through 1 heat cycle to ensure combustion air and vent pipes are properly c...

Page 30: ...4 distance is maintained The air intake screen can be removed for space heating at cold climate installation to prevent potential air intake freeze up If air intake screen is removed during winter to prevent freezing it is recommended to re install the screen during non space heating seasons If necessary to achieve the 12 minimum clearance above the highest anticipated snow level or grade for the ...

Page 31: ...gs 6 inches 15 2cm and above 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 Primer and Cement Tetrahydrofuran THF primer should be used to prepare the surfaces of pipe and fittings for solven...

Page 32: ... distance and make a second mark as the primer and cement will most likely destroy your first one Apply primer to the surface of the pipe and fitting socket with a natural bristle brush This process softens and prepares the PVC or CPVC for the solvent cementing step Move quickly and without hesitation to the cementing procedure while the surfaces are still wet with primer E Application of solvent ...

Page 33: ... 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 BLOCKED INTAKE SWITCH SEE FIGURE 33 The Blocked Intake Switch is set up to shut the unit off when a build up of negative pressure in the intake air pipe occurs This switch is a negative pressure switch ...

Page 34: ...RRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION VERIFY PROPER OPERATION AFTER SERVICING POWER VENT WIRING SCHEMATIC Figure 34 THIS WATER HEATER IS POLARITY SENSITVE BEFORE APPLYING ELECTRICITY TO THIS HEATER BE CERTAIN THAT SUPPLY NEUTRAL WIRE TO GROUND CHECK INDICATES ZERO VOLTAGE ...

Page 35: ...ced OPERATING INSTRUCTIONS 1 Set the thermostat to the lowest setting 2 Set the ON OFF switch on the control panel to the OFF position 3 Turn off all electrical power to the appliance if service is to be performed BEFORE OPERATING ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES 1 STOP Read the safety information above on this label 2 Set the ON OFF switch on the control panel...

Page 36: ... and on again to reset the control system Contact your dealer or servicer if continued high limit switch operation occurs 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 opera...

Page 37: ...nside 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 The main components of the control system are a UIM user interface module and a CCB central control board Th...

Page 38: ...Igniter is being energized The Igniter has been energized and the control system has sensed the required minimum igniter current The check mark icon is visual confirmation of minimum igniter current GAS OFF O N The 24 Volt Gas Valve is being energized The control system has sensed flame at the Main Burner from the Flame Sensor The control system has declared a Fault condition and must be inspected...

Page 39: ... the control system Note Cycling power will not reset the control system if the condition that caused the Fault has not been corrected Control System Menus From the Desktop screen pressing the Operational button directly below Menu on the LCD will display the Main Menu this is where all control system menus are located The table below describes the control system menus Table 5 Menu Description Tem...

Page 40: ...t and description of control system menus Use the Up and Down Buttons to view all control system menus from the Main Menu With Temperatures menu selected highlighted in black in the Main Menu screen press the Operational Button under SELECT to enter the Temperatures menu If the Temperatures menu is not selected use the Up and Down Buttons to select this menu item Temperatures Heater Status Display...

Page 41: ...urrent Operating State see Table 4 for a description of the various operational states ECO Contact Blocked Inlet PS Blocked Outlet PS Blower Prover PS displays the current state of the switch contacts open or closed Blower Low On Blower High On displays whether the blower is running at high speed during Pre Post purge and the Heating operational states or the blower is running at low speed during ...

Page 42: ...the control system water heater has been energized Burner On Time Total accumulated time the control system has been in the heating operating state burner run time Cycle Count Total accumulated count of heating cycles CCB Version Software version for central control board UIM Version Software version for user interface module Note Historical data is stored in the CCB s memory If this CCB is replac...

Page 43: ...iew details for each Fault or Alert message stored Note fault history memory is cleared after 30 days 1 Blocked Air Intake A7 51 mins ago 2 Blocked Exhaust A8 54 mins ago 3 Low Gas Pressure A6 57 mins ago 4 Blower Prover Failure AC VIEW BACK HELP Fault History Fault Occurrence Description Action Display Select Fault Occurrence from the Main Menu and press the Operational Button under SELECT to ent...

Page 44: ... Contact Information Yes Change Contact Name Change Contact Phone Current Contact Info 000 000 0000 Access Code UPDATE CANCEL Service Contact Information Using the UP and DOWN buttons select highlighted in black the Change Contact Name menu item Press the Operational Button under SELECT to open the Change Contact Name menu Show Contact Information Yes Change Contact Name Change Contact Phone Curre...

Page 45: ...ll cause a reaction between this rod and the water The most 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 a A concentration of sulfate in the supply water b Little or no dissolved oxygen in the water c A sulfate reducing bacteria which has accumulated within the wa...

Page 46: ... 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 A special anode rod may be available if water odor or discoloration occurs NOTE This rod may reduce but not eliminate water odor problems The water supply system may require special filtration equipment from a water conditionin...

Page 47: ...ve 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 9 Close the hot water faucet opened in Step 4 10 If the water heater is going to be shut down for an extended period the drain valve should be left open To Flush the Water Heater Stora...

Page 48: ...ture Pressure Relief Valve on page 17 for instructions on replacement DISCHARGE PIPE TEMPERATURE PRESSURE RELIEF VALVE Figure 37 If the Temperature Pressure Relief Valve on the water heater weeps or discharges periodically this may be due to thermal expansion Note Excessive water pressure is the most common cause of Temperature Pressure Relief Valve leakage Excessive water system pressure is most ...

Page 49: ... drain valve may be due to the valve being slightly opened F The drain valve may be leaking at the tank fitting G Leakage from recirculation plug or pipe connection H Leakage from the plug under the cleanout cover I Leakage from the temperature probe connection J Condensate from the exhaust connection Leakage from other appliances water lines or ground seepage should also be checked To check where...

Page 50: ...s de energized and will coast to a stop 13 Thecontrolsystemnowentersthestandbymodewhilecontinuing to monitor the internal storage tank water temperature and the state of other system devices If the tank temperature drops below the Operating Set Point minus the Differential setting the control will automatically return to Step 2 and repeat the operating cycle Installation Checklist The list below r...

Page 51: ...by control system Igniter is energized for warm up period 24 V Gas Valve is energized gas flows to Main Burner Is flame sensed at the Main Burner control system monitors the flame sensor Control System Locks Out Displays Fault Msg NO Control System Locks Out Blower Prover Open Fault Msg is displayed NO Control System Locks Out Low Igniter Current Fault Msg is displayed NO Combustion Blower is ener...

Page 52: ... a Fault condition it will display a Fault message on the control system s LCD with an exclamation mark The control system will lock out and disable heating operation until the condition is corrected The water heater must be serviced by a qualified service agent before operation can be restored Alert Conditions When the control system declares an Alert condition it will display an Alert message on...

Page 53: ...surface igniter is at ignition temperature causing delayed ignition which can cause a fire or explosion 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 Resetting Control System Lock Outs To reset the control system from a lock out condition turn the power supply off for approximately 20 ...

Page 54: ... CHANGE BACK ADVANCED Ignition Failure Fault occurred 2 mins ago The water heater has failed to ignite the burner Call a service professional Your Company Name Here press DOWN for more The control system has detected low current AC amps from the Hot Surface Igniter The control system monitors igniter current and will declare this Fault condition if the current is not at or above the programmed min...

Page 55: ...ce tube Combustion Blower is not running when energized Loose or open wiring to Combustion Blower CHANGE BACK ADVANCED Blower Prover Open Fault occurred 2 mins ago The blower prover switch remains open after the blower has been energized Call a service professional Your Company Name Here press DOWN for more The control system has detected the Blocked Intake Air Switch contacts are open Loose or op...

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Page 59: ...e heater is connected to unless an effective method of controlling thermal expansion is also installed at the heater s and operational at all times The temperature and pressure relief valve installed on the heater is not an acceptable method SERVICE AND REPAIR EXPENSES 4 Under the limited warranty the warrantor will provide only a replacement water heater or part thereof The owner is responsible f...

Page 60: ...500 Tennessee Waltz Parkway Ashland City TN 37015 Phone 800 527 1953 Fax 800 433 2515 www statewaterheaters com ...

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