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State Water Heaters GS 6 Installation And Operating Manual Download Page 54

PROBLEM

POSSIBLE CAUSE(S)

CORRECTIVE ACTION

BLOWER RUNS 

CONTINUOUSLY

1.  Air pressure switch not closing due to 

insuf

fi

 cient draft – check for:

  a.  Vent piping blocked
  b.  Piping length too long
 c. 

Clogged/dirty 

blower

2.  Disconnected, torn or blocked pressure 

switch hose from air pressure switch to 
blower housing

3.  Defective pressure switch
4.  High limit switch open due to excessive 

vent temperature or defective switch

1.  Determine cause of insuf

fi

 cient 

draft. Check draft with manometer at 
pressure switch

 a. 

Remove 

blockage

  b. Reduce vent length/increase vent 

size

  c.  Clean blower wheel
2.  Reconnect or replace pressure switch 

hose

3.  Replace defective pressure switch
4.  Determine cause of overheating check 

for: over

fi

 ring, insuf

fi

 cient air supply, 

high ambient air temperature

HOT SURFACE IGNITER 

NOT GLOWING 

FOLLOWING WARM-UP 

PERIOD

1.  120VAC polarity reversed at 120VAC 

outlet receptacle

2.  Defective hot surface igniter
3.  Defective gas control valve/thermostat

1.  Reverse polarity at 120VAC outlet 

receptacle

2. Replace 

igniter

3.  Replace gas control valve/thermostat

VENT PIPE TOO HOT

1.  Blower high limit switch fails to open - 

switch defective

2.  Not enough dilution air to mix with 

fl

 ue 

gases

3.  Air in room too hot for mixing with 

fl

 ue 

gases

4.  Wrong burner ori

fi

 ce

1.  Replace blower high limit switch Replace 

blower high limit switch

2.  Proper air circulation must be provided 

for combustion and dilution of 

fl

 ue temp

3.  Increase ventilation to lower room 

temperature

4.  Install correct ori

fi

 ce.

 RESETTING THE HEATER CONTROL

• 

Soft lockouts as diagnosed by the system error codes 
require the gas control to be reset.

• 

To reset the control, slide the “ON/OFF” switch to the 
“OFF” position. Wait for 10 seconds and move the 
switch back to the “ON” position.

• 

If the problem that caused the control to lock out has 
not been corrected, the control will remain or again go 
back into lockout.

 LOCKOUTS
 Soft  Lockout

• 

occurs when a system safety device trips to break the 
sequence of operation. The control will retry the system 
in a timed basis but will not reinstate operation until the 
failure is corrected.

 Hard  Lockout

• 

occurs when the main controller fails and must be 
replaced.

The gas control valve\thermostat includes a temperature 
limiting ECO (Energy Cut Off) system that will shut off the 
water heater if the water temperature is too high.
Should the water temperature get too high, the diagnostic 
status light will indicate a code (4 

fl

 ashes), indicating an 

over-temperature condition and the main burner will be 
shut off. If a high temperature condition occurs, turn the 
main gas supply OFF and have the water heater repaired 
by a quali

fi

 ed service technician. Contact your local dealer 

for service information.

Note:

 Should an over-temperature condition occur, restart 

the water heater and verify the LED 

fl

 ash sequence. If the 

4 

fl

 ash sequence is observed, slide the “ON/OFF” switch to 

the “OFF” position. Turn Main Gas Supply “OFF”. Replace 
the gas control valve\thermostat. See “Removing and 
Replacing the Gas Control Valve/Thermostat.”

54 www.statewaterheaters.com 

Summary of Contents for GS 6

Page 1: ...ER VENTED GAS MODELS WITH HOT SURFACE IGNITION NOT FOR USE IN MANUFACTURED MOBILE HOMES 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 IF YOU ARE UNSUCCESSFUL PLEASE CONTACT THE COMPANY LISTED ON THE RATING PLATE ON THE WATER HEATER www statewaterheaters co...

Page 2: ...ltitude Installation 24 Gas Piping 24 Sediment Traps Dirt Leg 25 Filling The Water Heater 26 Venting 26 Termination Clearances Sidewall Power Vent 27 Blower Assembly Installation 28 Installation Of Vent System 28 Planning The Vent System 28 High Ambient Temperature Installations 28 Polypropylene Vent Systems 29 Condensate 29 Exhaust Venting 30 Important Notes and Warnings Venting terminations and ...

Page 3: ...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 IMPORTANT DEFINITIONS Qualified Installer A qualified installer must have ability equivalent to a licensed tradesman in the fields of plumbing ...

Page 4: ...GENERAL SAFETY 4 www statewaterheaters com ...

Page 5: ... 2 are heavier than air 3 go a long way on the floor and 4 can be carried from other rooms to the the electodes by air currents Flammable Vapors FLAMMBLE DANGER Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual Install vent system in accordance with codes Do not operate water heater if flood damaged For operation above 10 100 a high altitude or...

Page 6: ...This manual contains instructions for installation operation and maintenance of the gas fired water heater It also contains warnings throughout the manual that you must read and be aware of All warnings and instructions are essential to proper operation of the water heater and your safety Since we cannot put everything on the first few pages READ ENTIRE MANUAL BEFORE ATTEMPTING TO INSTALL OR OPERA...

Page 7: ...ontally 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 observes carbon monoxide detectors and si...

Page 8: ...ON REQUIREMENTS 1 CONNECT ELECTRONICALLY CONTROLLED TIMER TO AN ALL BRONZE PUMP PUMP MUST ACTIVATE EVERY 6 HOURS FOR 60 SECONDS TURN PUMP TIMER OFF BEFORE CLOSING PIPING LOOP SHUT OFF VALVE 2 ALL WATER PIPING MUST BE INSTALLED AND INSULATED IN ACCORDANCE WITH MASSACHUSETTS CODE 248 CMR 780 CMR 3 PIPING LOOP BETWEEN WATER HEATER AND AIR HANDLER MUST BE INSTALLED IN COMPLIANCE WITH 248 CMR REQUIRED ...

Page 9: ...ing see Figure 6 26 Rubber Coupling see also Figure 6 27 Gear Clamp see also Figure 6 28 Flue Collector 29 Hot Water Outlet Nipple 30 Anode under cap 31 Control Harness 32 Flexible Manifold Tube see Figure 3 Figure 4 33 Viewport see Figure 3 Figure 4 34 Flame Sensor Rod see Figure 3 Figure 4 35 Gas Orifice see Figure 3 Figure 4 36 Sheet Metal Burner see Figure 3 Figure 4 37 Gas Manifold see Figure...

Page 10: ...ss has 120 VAC In operation See Planning The Vent System Condensate and Blower Assembly Installation for more information REPLACEMENT PARTS AND DELIMING PRODUCTS Replacement parts and recommended delimer may be ordered through authorized servicers or distributors When ordering parts provide complete model and serial numbers see rating plate quantity and name of part desired Standard hardware items...

Page 11: ...RT 9001262 CAN BE ORDERED THROUGH THE MANUFACTURER NOTE THE T P VALVE DISCHARGE PIPE MUST BE PIPED DIRECTLY TO THE DRAIN OR EXTERNAL TO THE BUILDING MASSACHUSETTS INSTALL A VACUUM RELIEF IN COLD WATER LINE PER SECTION 19 MGL 142 Figure 8 his appliance has been design certified as complying with American National Standard CSA Standard for water heaters and certain models with side plumbing connecti...

Page 12: ... 8 Figure 9 or at hot water taps to further reduce system water temperature 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 Before changing the factory setting on the thermostat read the Operating The Temperature Control System section in this manual WATER HEATER OPE...

Page 13: ...for the correct electrical connections After making all electrical connections completely fill the tank with water and check all connections for leaks Open the nearest hot water faucet and let it run for 3 minutes to purge the water lines of air and sediment and to ensure complete filling of the tank The electrical power may then be turned on Verify proper operation after servicing See also Instal...

Page 14: ...ble vapors before they enter the combustion chamber this water heater is equipped with a flammable vapor sensor FVS It is a chemical absorption based sensor that is connected to the gas control thermostat see Figure 13 When exposed to flammable vapors it will trigger the control to stop the flow of gas and enter the FVS lockout state While in the FVS lockout state the LED on the control will flash...

Page 15: ...to an adequate drain The pan must have a maximum depth of 1 75 Water heater life depends upon water quality water pressure and the environment in which the water heater is installed Water heaters are sometimes installed in locations where leakage may result in property damage even with the use of a metal drain pan piped to a drain However unanticipated damage can be reduced or prevented by a leak ...

Page 16: ... every direction or if the appliance is installed 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 Clearance for servicing Adequate clearance of 24 for servicing this appliance should be considered before installation such as changing the anodes etc A minimum clearance of 5 5 must be allowed for access to replaceable part...

Page 17: ...r safe operation an adequate supply of fresh uncontaminated air for combustion dilution and ventilation must be provided Note Contaminated or dusty air may cause build up on the blower wheel resulting in nuisance shut downs An insufficient supply of air can cause recirculation of combustion products resulting in contamination that may be hazardous to life Such a condition often will result in a ye...

Page 18: ...frigerants swimming pool chemicals calcium and sodium chloride water softener salt waxes bleach and process chemicals are typical compounds which are potentially corrosive A ALL AIR FROM INSIDE BUILDINGS See Figure 16 The confined space shall be provided with two permanent openings communicating directly with an additional room s of sufficient volume so that the combined volume of all spaces meets...

Page 19: ...nt free area Louvers and grilles shall be fixed in the open position or interlocked with the equipment so that they are opened automatically during equipment operation 7 Special Conditions Created by Mechanical Exhausting or Fireplaces operation of exhaust fans ventilation systems clothes dryers or fireplaces may create conditions requiring special attention to avoid unsatisfactory operation of in...

Page 20: ...tting on thermostat read Operating The Temperature Control System section in this manual This water heater should not be connected to any heating systems or components previously used with a non potable water heating appliance All piping components connected to this unit for space heating applications should be suitable for use with potable water Toxic chemicals such as those used for boiler treat...

Page 21: ...t loss 7 If the local jurisdiction requires a back flow preventer in the cold water line an expansion tank of adequate size must be installed 8 Combo Heating Systems require higher water temperatures than other applications When the system is used to supply water for Combo Heating applications a means such as mixing valve must be installed to temper the water in order to reduce scald hazard potent...

Page 22: ...sed systems to control the harmful effects of thermal expansion Contact a plumbing service agency or your retail supplier regarding the installation of a thermal expansion tank Note To protect against untimely corrosion of hot and cold water fittings it is recommended that di electric unions or couplings be installed on this water heater when connected to copper pipe Avoid water heater damage Inst...

Page 23: ...h over 30 feet 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 T P valve and the tank Do not connect discharge piping directly to the drain unless a maximum of 6 air gap is provided To prevent bodily injury hazard to life or property damage the relief valve must be allowed to discharge wa...

Page 24: ... heater 4 Locate the slit running the length of a section of pipe insulation 5 Spread the slit open and slip the insulation over the cold water inlet pipe Apply gentle pressure along the length of the insulation to ensure that it is fully seated around the pipe Also ensure that the base of the insulation is flush with the water heater Once seated secure the insulation with duct tape electrical tap...

Page 25: ... tape compatible with propane Leak test before operating heater Disconnect gas piping and shut off valve before pressure testing system Fire and Explosion Hazard WARNING Use pipe joint compound or Teflon tape marked as being resistant to the action of gases The appliance and its gas connection must be leak tested before placing the appliance in operation The appliance and its individual shut off v...

Page 26: ... between the heater and the faucets are the open position 4 Open the cold water supply valve to the water heater Notes The cold water supply valve must be left open when the water heater is in use Avoid water leakage when filling the tank Do not allow the insulation of the water heater to get wet as water can reduce the effectiveness of the insulation 5 To ensure complete filling of the tank allow...

Page 27: ...ow or to side of opening 1 foot above opening D Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 ft from the center line of the terminal 12 in K Clearance to a mechanical air supply inlet 3 ft above if within 10 ft horizontally E Clearance to unventilated soffit 12 in L Clearance above paved sidewalk or paved driveway located on public property 7...

Page 28: ...ipe To start off with an elbow a short section of the straight pipe must be cut and glued into the end of the elbow that will mount on the discharge boot INSTALLATION OF VENT SYSTEM Before beginning installation of piping system thoroughly read the Vent Pipe Preparation section of this manual PLANNING THE VENT SYSTEM Plan the layout of the vent system from the vent termination to the water heater ...

Page 29: ...connection is required and is available through your supplier Optional wall plates that fit the polypropylene venting are also available through your supplier Carefully inspect the entire venting system for any signs 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 resul...

Page 30: ...y use approved material All venting material and components must be joined with the approved primer cleaner and solvent cement Do not common vent this heater with any other appliance During operation the plastic piping will expand as it heats up and contract as it cools down This is normal for this type of venting Rigidly fastening the vent piping can cause undue stress that may result in the crac...

Page 31: ...ing to attach the venting to the blower and a 3 45 vent termination elbow Supplied with this heater are several vent termination screens see Figure 31 Figure 32 Installed in the vent termination elbow the vent screen is required to keep foreign objects rodents and small birds from entering the venting system These screens have been sized to ensure maximum energy efficiency of the vent system based...

Page 32: ... Long Sweep Long Radius Notes 1 Use long radius elbows where possible Minimum distance between 90º elbows should be 6 wherever possible 2 Venting systems may use a maximum of five 5 90 elbows 3 Use proper screen termination see Figure 31 Figure 32 2 3 4 90 elbow 8 ft 5 ft 2 3 4 45 elbow 4 ft 2 5 ft Table 2 Example for calculating equivalent feet Section A 0 5 ft 90 elbow 8 0 ft Section B 1 0 ft 45...

Page 33: ...the vent piping through this hole and secure into position Connect the vent pipe to the end termination elbow as shown in Figure 34 thru Figure 36 10 Dry fit all vent pipes elbows connectors and fittings before joining any parts with solvent cement PARTS MUST FIT WITHOUT STRESS OR BENDING OF ANY SECTION and each connection must overlap a minimum of 1 2 Do not force fit any of the connections Use o...

Page 34: ...ubber coupling Check that there is no stress on the connection or the vent piping that may be caused by twisting or bending 6 Tighten the upper clamp so that the vent piping is firmly secured in the coupling and is gas tight Do not over tighten or cause distortion of any of the parts Ensure the bottom of the rubber coupling is firmly seated on the blower outlet and that the lower gear clamp is als...

Page 35: ...you have any questions about the application or installation of PVC and CPVC pipe Take the time and effort to do a professional job Shortcuts will only cause you problems and delays in start up By far the majority of failures in PVC and CPVC systems are the result of shortcuts and or improper joining techniques 2 SELECTION OF MATERIALS PCV and CPVC VENTING Cutting Device Saw or Pipe Cutter Deburri...

Page 36: ...proper interfacing of the pipe end and the fitting socket bottom This can be accomplished with a miter box saw or wheel type cutter Wheel type cutters are not generally recommended for larger diameters since they tend to flare the corner of the pipe end If this type of cutter is used the flare on the end must be completely removed Note Power saws if used should be specifically designed to cut plas...

Page 37: ...ing socket Avoid puddling Apply a second coat of cement to the pipe end Cans of cement and primer should be closed at all times when not in use to prevent evaporation of chemicals and hardening of cement They are also very flammable and should be kept away from heat or flame Fire Hazard WARNING Figure 45 F Joint assembly Working quickly insert the pipe into the fitting socket bottom and give the p...

Page 38: ...Located as close to gas piping and vent pipe system as possible 2 Located indoors and in a vertical position Protected from freezing temperatures 3 Proper clearances from combustible surfaces maintained and not installed directly on a carpeted floor 4 Provisions made to protect the area from water damage Metal drain pan installed and piped to an adequate drain 5 Installation area free of corrosive...

Page 39: ...ight manually 6 Wait five 5 minutes to clear out any gas If you then smell gas STOP Follow B in the safety information above on this label If you don t smell gas go the next step 7 Turn on all electric power to the appliance 8 Set the switch on the control to the ON position 9 Turn thermostat to desired setting DANGER Hotter water increases the risk of scald injury Consult the instruction manual b...

Page 40: ...iring certain temperature water at the hot water tap then you must take special precautions In addition to using the lowest possible temperature setting that satisfies your hot water needs a means such as a mixing valve should be used at the hot water taps used by these people or at the water heater Mixing valves are available at plumbing supply or hardware stores see Figure 8 Figure 9 Follow manu...

Page 41: ...nds HOT 120 More than 5 minutes LOW 110 Normal shower temp VAC 70 N A Table 4 Note The temperatures indicated are approximates The actual temperature of the heated water may vary The Vacation Setting VAC sets the controller at approximately 70 F This setting is recommended when the water heater is not in use for a long period of time This effectively turns the controller temperature setting down t...

Page 42: ...cy or your retail supplier regarding the installation of a thermal expansion tank Closed water systems See Closed Water Systems section elsewhere in this manual 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 Strange sounds Possible noises due to expansion...

Page 43: ... explosive To prevent the possibility of injury under these conditions it is recommended that the hot water faucet located farthest away be opened for several minutes before any electrical appliances which are connected to the hot water system are used such as a dishwasher or washing machine If hydrogen gas is present there will probably be an unusual sound similar to air escaping through the pipe...

Page 44: ...all the local gas utility to correct the problem and clean or replace the flue and venting before resuming operation of the water heater BLOWER MAINTENANCE Inspect the top of the heater and around the ventilation openings of the blower motor and the rear blower dilution air intakes for any lint and dust that may have accumulated Depending on the location of the heater significant quantities of lin...

Page 45: ...NG BLOWER FLUE COLLECTOR HOOD 11 32 NUTS MOUNTING PLATE GEAR CLAMP VENT PIPE MOTOR Figure 49 BURNER OPERATION AND INSPECTION 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 Contact a qualified installer or service a...

Page 46: ...Artificially softened water can be exceedingly corrosive because the process substitutes sodium ions for magnesium and calcium ions The use of a excessively soft water may decrease the life of the water heater tank The anode rod should be inspected after a maximum of three years and annually thereafter until the condition of the anode rod dictates its replacement Note Artificially softened water r...

Page 47: ... DANGER It is recommended that the temperature pressure relief valve be checked to ensure it is in operating condition at least once a year When checking the temperature pressure relief valve operation make sure that 1 no one is in front of or around the outlet of the T P valve discharge line and 2 that water discharge will not cause any property damage as water may be extremely hot Use care when ...

Page 48: ...heater is going to be shut down and drained for an extended period the drain valve should be left open with hose connected allowing water to terminate to an adequate drain 6 Close the water heater drain valve when all water in the storage tank has drained 7 Follow instructions in the Filling the Water Heater section 8 Turn ON the gas supply at the main gas shut off valve 9 Follow the lighting inst...

Page 49: ...m temperature pressure relief valve may be due to thermal expansion or high water pressure in your area E The temperature pressure relief valve may be leaking at the tank fitting F Water from a drain valve may be due to the valve being slightly opened G The drain valve may be leaking at the tank fitting H Combustion products contain water vapor which can condense on the cooler surfaces of the tank...

Page 50: ...et Snorkel 20 Combo Heating System Supply Outlet Optional 21 Blower with Power Cord see also Figure 61 22 Air Switch inside box see Figure 61 23 Junction Box see Figure 61 24 Junction Box Cover see Figure 61 25 Air Tubing see Figure 61 26 Rubber Coupling see also Figure 61 27 Gear Clamp see also Figure 61 28 Flue Collector 29 Hot Water Outlet Nipple 30 Anode under cap 32 Flexible Manifold Tube see...

Page 51: ...al gas and Propane main burner with igniter assembly for 60k to 75k Btu hr models Flare Nut Figure 59 17 Figure 60 25 23 24 22 5 26 27 21 Figure 61 Notes Natural gas models have Right hand thread Propane models have Left hand thread For Natural gas models the Flare Nut has Right hand thread For Propane models the Flare Nut has Left hand thread www statewaterheaters com 51 ...

Page 52: ...ve gas control valve thermostat 1 Turn temperature knob to lower setting 2 Replace the gas control valve thermostat SLOW HOT WATER RECOVERY 1 Insufficient air flue blockage 2 Low gas pressure 3 Orifice too small 4 Thermostat set too low 5 Heater too small 6 Wrong piping connection 7 Wasted hot water 8 Flue clogged 9 Air inlets blocked 1 Provide ventilation to water heater Check flue way flue baffl...

Page 53: ...ice see rating plate 5 Clean locate source and correct 6 Replace gas control valve thermostat 7 Provide fresh air ventilation UNABLE TO LIGHT THE BURNER 1 Air in gas line 2 Pressure switch 3 Blocked exhaust 4 Wire connection 5 Defective gas control valve thermostat 1 Purge the air from gas line 2 Check the pressure switch make sure the pressure switch hose is not kinked 3 Check vent pipe for block...

Page 54: ...ncrease ventilation to lower room temperature 4 Install correct orifice RESETTING THE HEATER CONTROL Soft lockouts as diagnosed by the system error codes require the gas control to be reset To reset the control slide the ON OFF switch to the OFF position Wait for 10 seconds and move the switch back to the ON position If the problem that caused the control to lock out has not been corrected the con...

Page 55: ...e the problem before attempting corrective action See also Flammable Vapor Sensor LED Flash Sequence Control Status Short flash once every four seconds IDLE no call for heat no fault conditions Heartbeat alternates bright dim Call For Heat no fault conditions One Flash three second pause Low Flame Signal control continues to operate Two Flash three second pause Pressure Switch Failed Closed Three ...

Page 56: ...This page intentionally left blank May be used for notes or to record other installation information 56 www statewaterheaters com ...

Page 57: ...This page intentionally left blank May be used for notes or to record other installation information www statewaterheaters com 57 ...

Page 58: ... the working pres sure shown on the heater filled with potable water free to circulate at all times and with the tank free of damaging water sediment or scale deposits used in a non corrosive and non contaminated atmo sphere used with factory approved anode s installed in its original installation location in the United States its territories or possessions and Canada sized in accordance with prop...

Page 59: ...nd City TN 37015 phone 1 800 821 2017 The warrantor will only honor replacement with identical or similar water heater or parts thereof which are manufactured or distributed by the warrantor Dealer replacements are made subject to in warranty validation by warrantor PROOF OF PURCHASE AND PROOF OF INSTALLATION DATE ARE REQUIRED TO SUPPORT WARRANTY CLAIM FROM ORIGINAL OWNER THIS FORM DOES NOT CONSTI...

Page 60: ...500 Tennessee Waltz Parkway Ashland City TN 37015 Phone 800 821 2017 Fax 800 644 9306 Website www statewaterheaters com ...

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