State Industries GP6 50 HTPDT 120 Series manual

1 Instruction Manual PRINTED 0410 317447-000 KEEP THIS MANUAL IN THE POCKET ON HEA TER FOR FUTURE REFERENCE WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED. POWER VENT/POWER DIRECT VENT GAS MODELS WITH HOT SURF ACE IGNITION ALL TECHNICAL AND W ARRANTY QUESTIONS: SHO ULD BE DI REC TED T O T HE LO CA L DEA LER FRO M WHO M TH E W A T ER HEA TE [...]

2 T ABLE OF CONTENTS T ABLE OF CONTENTS ........................................................................2 SAFE INST ALLA TION, USE AND SERVICE........................................3 APPROV ALS ........................................................................................3 GENERAL SAFETY INFORMA TION .............................[...]

3 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 through[...]

4 PRECAUTIONS DO NOT USE THIS APPLIANCE IF ANY P ART HAS BEEN UNDER W A TER. Immediately call a qualied service agency to inspect the appliance and to make a determination on what steps should be taken next. If the unit is exposed to the following, do not operate heater until all corrective steps have been made by a qualied service agency . 1[...]

5 GENERAL SAFETY INFORMA TION[...]

6 Fire Hazard Do not install water heater on carpeted floo r. Do not operate water heater if flood damaged. For continued protection against risk of fire: Fire or Explosion Hazard Read instruction manual before installing, using or servicing water heater . Av oid all ignition sources if you smell gas. Do not store or use gasoline or other flammable[...]

7 Thank Y ou for purchasing this water heater . Properly installed and maintained, it should give you years of trouble free service. ABBREVIA TIONS USED Abbreviations found in this Instruction Manual include : • ANSI - American National Standards Institute • ASME - American Society of Mechanical Engineers • GAMA - Gas Appliance Manufacturer ?[...]

8 * CAUTION HARNESS HAS 120 VAC. IN OPERATION. * * See “Pla nnin g th e Ve nt S yste m,” “Ins tall ation of Vent Sys tem” and “Co nden sate Piping” fo r mo re in form atio n. FIGURE 1. V ACUUM RELIEF V AL VE *INST ALL PER LOCAL CODES M Display Enclosure ** N Exhaust Elbow Assembly ** O Condensate T ubing P Off/On Switch Q Display Label [...]

9 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 T op/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 T ype “WC kP A V olts/Hz Amperes [...]

10 LOCA TING THE W A TER HEA TER 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. Property Damage Hazard All water heaters eventually leak. • Do not install without adequate drainage. • CAUT ION[...]

11 in an alcove or closet, the entire oor must be covered by the panel. Failure to heed this warning may result in a re hazard. Minimum clearances between the water heater and combustible con stru ctio n are 0 i n c h at the side s a n d rear , 5. 5” (14.0 cm) from the fro nt and 18” (45.7 cm) from the top. (Stand ard clearance .) If cl e[...]

12 ventilation systems, clothes dryers and replaces shall also be considered in determining the adequacy of a space to provide combustion, ventilation and dilution air . UNUSUALL Y TIGHT CONSTRUCTION In unconned spaces in buildings, inltration may be adequate to provide air for combustion, ventilation and dilution of ue gases. However ,[...]

13 1. 1 square inch per 3000 Btu/hr (700 mm 2 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 HORIZONT AL DUCTS FIGURE 6. The conned space shall be provided with two permanent horizontal ducts, one commencing withi[...]

14 This water heater shall not be connected to any heating systems or component(s) used with a non-potable water heating appliance. All piping components connected to this unit for space heating applications shall be suitable for use with potable water . T oxic chemicals, such as those used for boiler treatment shall not be introduced into this sys[...]

15 MIXING V AL VES Wa ter temperature over 125°F (52°C) can cause severe burns instantly resulting in severe injury or death. Children, the elderly and the physically or mentally disabled are at highest risk for scald injury . Feel water before bathing or showering. Te mperature limiting devices such as mixing valves must be installed when requir[...]

16 FIGURE 9. CLOSED W A TER SYSTEMS W ater 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 ow preventers. Devices such as these cause the water system to be a closed system. THERMAL EXP ANSION As water is heat[...]

17 Fit pipe insulation over the incoming cold water line and the hot water line. Make sure that the insulation is against the top cover of the heater .Fit T & P valve insulation over valve. Make sure that the insulation does not interfere with the lever of the T & P valve. Secure all insulation using tape. TEMPERA TURE-PRESSURE RELIEF V AL [...]

18 GAS PIPING Make sure gas supplied is same type listed on model rating plate. The inlet gas pressure must not exceed 14 inch water column (3.5 kPa) for natural and propane gas (L.P .). The minimum inlet gas pressure shown on rating plate is that which will permit ring at rated input. All gas piping must comply with local codes and ordinances o[...]

19 HIGH AL TITUDE INST ALLA TIONS This high efciency water heater is certied for use without modication for an altitude of 10,000 feet (3,079 meters). Consult the factory for installation at altitudes over 10,100 feet (3,079m). Some gas utility companies derate their gas for altitude, making it unnecessary to install high altitude orice[...]

20 VENTING Never operate the water heater unless it is vented to the outdoors. The instructions in this section of the manual must be followed to avoid choked combustion or recirculation of ue gases. Such conditions cause sooting of the combustion chamber , burners and ue tubes and creates a risk of asphyxiation. VENT PIPE TERMINA TION The ?[...]

21 PVC M ater ial s s hou ld use ASTM D-25 6 4 Gr ade Cem ent; CPVC Ma te r i a ls sh o ul d use AS T M F- 4 9 3 G r a de C e me nt an d A B S Mate ri als sh oul d use A STM D -2 2 35 G rad e Ce ment . If the water heate r i s being ins tal led as a r epla ce ment for an exist ing power vented heater in p re - exi sti ng venting, a t ho rou gh insp[...]

22 COMMONWEAL TH OF MASSACHUSETTS 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 t[...]

23 TERMINA TION CLEARANCES SIDEW ALL POWER VENT V X VEN T TERMINAL AIR SUPPL Y INLE T A RE A WHERE TERMINAL IS NO T PERMITTED v v A G V FIXE D CLOSED FIXE D CLOSED OPERABLE OPERABLE V C B B B B F B V V A J V H M X X V V K B E D L POWER VENT (using room air for combustion) EXTERIOR CLEARANCES FOR SIDEW ALL VENT TERMINA TION FIGURE 13 V ent terminal [...]

24 TERMINA TION CLEARANCES SIDEW ALL DIRECT VENT V X VENT TERMINAL AIR SUPPL Y INLE T A RE A WHERE TERMINAL IS NO T PERMITTED v v A G V FIXE D CLOSED FIXE D CLOSED OPERABLE OPERABLE V C B B B B F B V V A J V H M X X V V K B E D L DIRECT VENT (using outdoor air for combustion) EXTERIOR CLEARANCES FOR SIDEW ALL VENT TERMINA TION FIGURE 14 V ent termi[...]

25 SEQUENCE OF INST ALLA TIONS, FIGURE 15A Cut a length of PVC pipe about 3.5 inches (8.9 cm ) longer than the w a l l t h i c k n e s s a t t h e o p e n i n g . G l u e t h e v e n t t e r m i n a l t o t h i s s e c t i o n o f pi pe . Sli de th e wa ll pl at e ov er the pipe to st op aga in st th e ve nt te rmi na l . Pla ce a bea d o f caulki [...]

26 VERTICAL VENT TERMINAL INST ALLA TION WHEN TERMINA TING THROUGH A ROOF , THE FOLLOWING SPECIFICA TIONS PERT AINING TO TERMINAL LOCA TION 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 ashing. 3. The intake[...]

27 CONCENTRIC VENT INST ALLA TION This appliance is certied for concentric venting with concentric vent kit #9003910105 and #9006328005. Follow instructions below for proper installations. KIT COMPONENTS Each kit is comprised of the following: Item Description Qt y. Rain Cap 3 in. 1 SDR-26 pipe 4 in. dia. 1 SDR-26 pipe 2½ in. dia. 1 Y Concentri[...]

28 5 . S e c u r e a s se mb ly t o r o o f s t r uc t u r e a s s h o w n i n F i g u r e 2 3 u s i n g f i e l d s u pp li e d m e t a l s tr a p p i n g o r e qu i va l e nt s u p p o r t mater ial. NOT E: En su re t e r mi na t io n he i gh t is ab ove t he r oo f su r fac e or a nt ic ip at ed s now l evel a s show n in Fi gu re 23 . 6 . Ins t[...]

29 5. In sta ll ra in c ap and small d iamet er pip e as semb ly in Y c o nc entr ic t ti ng and la rge pi pe as sem bly . Ensure sm all dia meter pi pe is bot to med a nd c eme nted in Y c o nc entr ic  t tin g. 6. S ecu re ass emb ly to str uct ure as show n in Figur e 24 using el d - supp lie d met al str app ing o r equi valent s upp o[...]

30 12” MINIMUM CLEARANCE ABOVE HIGHEST ANTICI PAT ED SNOW LEVEL 12” MINIMUM CLEARANCE ABOVE HIGHEST ANTICI PA TED SNOW LEVEL 24” MINIMUM SEP ARA TION. EXHAUST MUST BE AT SAME LEVE L OR ABOVE INT AKE TERMINAL. DIRECT VENT DIAGRAM FIGURE 28. FIGURE 30. FIGURE 31. FIGURE 32. FIGURE 29. When direct venting through the wall, as shown in Figure 32,[...]

31 VENT PIPE PREP ARA TION 1. INITIAL PREP ARA TION. A.) Make sure the solvent cement you are planning to use is designed for the specic application you are attempting. B .) Know the physical and chemical characteristics and limitations of the PVC and CPVC piping materials that you are about to use. C.) Know the reputation of your manufacturer a[...]

32 B. Deburring Us e a k ni fe , pl as ti c p i pe de bur rin g t ool , o r f il e t o r em ov e b ur rs f ro m the end of small diameter pipe. Be sure to remove all burrs from ar oun d t he ins ide as wel l as the out si de of t he p ipe . A sli ght cha mf er (b eve l) of ab ou t 10 °- 15 ° s ho uld be ad ded to th e e nd to pe rmi t e as ier in[...]

33 CONTROLS AND SWITCHES This model is provided with thre e pres sure switches. Th ese switches are essential to the safe and proper operation of the unit. All switches are wired in series. The controller is set up to shut the unit down whenever there is a failure of any of the switches. It is important to understand the purpose of each switch. FIG[...]

34 CAUTION LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERA TION. VERIFY PROPER OPERA TION AFTER SERVICING. POWER VENT WIRING SCHEMA TIC - FIGURE 34. THI S WATER H E ATER IS P OL ARI T Y S ENSI T VE . B E F O R E A P P LY I N G ELECTRICITY TO TH IS H E ATE R B E C ER TAI N THA T SU[...]

35 W ARNING: If you do not follow these instructions exactly , a fire or explosion may result causing property damage, personal injury or loss of life. 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 OPERA TING smell all around [...]

36 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. V alves for reducing the point-of-use temperature by mixing cold and hot water are available, see Figure 8. Also available are i n e x p e n s i ve d e v i c e s t h a t at [...]

37 USER INPUT BUTTONS • The up and down buttons are used to navigate menus and adjust user settings. • The operational buttons are used to enter/exit menus, select menu items, activate adjustment modes and conrm or cancel new user settings. The operational buttons are multifunctional, their current function is dened by the text that appea[...]

38 ST A TUS ICONS The Status Icons are displayed on the Desktop screen and convey operational and diagnostic information. The icons are described in the table below . T ABLE 3. Icon Description W ater 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 t[...]

39 OPERA TING ST A TES 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 . T ABLE 4. State Description Standby The water heater is not in an active heating cycle. IE: the T ank T emperature is at or above the Operating Set Po[...]

40 USER SETTINGS & CONTROL SYSTEM MENUS TEMPERA TURES OPERA TING 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 [...]

41 TEMPERA TURES (CONT) DESCRIPTION/ACTION DISPLA Y T ank T emperature • - non adjustable - control system sensed temperature from the T emperature Probe. T ank Probe Offset • - adjustable user setting, range -5° to +5° (factory setting 0°). The T ank Probe Offset is used to calibrate control system temperature sensing. This can improve the [...]

42 DISPLA Y SETTINGS DESCRIPTION/ACTION DISPLA Y 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. T emperature Units • - Adjustable use[...]

43 CURRENT F AUL T DESCRIPTION/ACTION DISPLA Y 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. This menu contains the current Fault or Alert error message. The time the [...]

44 SERVICE CONT ACT INFORMA TION 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 DISPLA Y From the Desktop Screen press and hold down the middle (unmar[...]

45 ST ART UP CONDITIONS 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 of f of oil from metal parts, and will disappear in a short while. THERMAL EXP ANSION W ater supply systems may , because of such events as high line pressure, frequent cut-offs, the effects of wat[...]

46 VENTING SYSTEM INSPECTION At least once a year a visual inspection should b e made of the venting system. Y ou should look for: 1. Obst ruct io ns whic h cou ld caus e imp rope r ven ting . Th e com bust io n and ventilation air ow must not be obstructed. 2. Damage or deterioration which could cause improper venting or leakage of combustion p[...]

47 FIGURE 36. When checking the temperature-pressure relief valve operation, make sure that (1) no one is in front of or around the outlet of the temperature-pressure relief valve discharge line, and (2) that the water discharge will not cause any property damage, as the water may be extremely hot, see Figure 36. If after manually operating the val[...]

48 MAINTENANCE TEMPERA TURE-PRESSURE RELIEF V AL VE TEST Burn hazard. Hot water discharge. Keep clear of Te mperature- Pressure Relief V alve discharge outlet. It is recommended that the T emperature-Pressure Relief V alve should be checked to ensure that it is in operating condition every 6 months. When checking the T emperature-Pressure Relief V [...]

49 Never use this water heater unless it is completely lled with water . T o prevent damage to the tank, the tank must be lled with water . W ater must ow 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 ?[...]

50 TROUBLESHOOTING Flow Chart. 1. When the control system is rst powered, during boot up, it will display water heater model information during initialization. After a few moments the control system LCD which is part of the UIM (user interface module) will display the default screen known as the "Desktop" screen. 2. If the control syst[...]

51 SEQUENCE OF OPERA TION FLOW CHART YES NO Wa te r is hea t ed to se t po in t 24 V Ga s Va lv e de -e nerg iz ed Approximately 30 se co nd In te r- Pu rge cycl e 24 V Ga s Va lv e de- energi ze d Re tr ie s up to tw o mo re ti me s Approximately 30 se co nd Po st -P ur ge cycl e C ont r o l Sy st em Loc ks Ou t “I gni ti on Fa il ure” Fa ul t[...]

52 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.[...]

53 NOTE: If you are not qualied and licensed or certied 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. If you do not understand the instructions in the following section do not attempt to perform any procedures. [...]

54 F AUL T AND ALERT MESSAGES Call the technical support phone number listed on the back cover for further technical assistance or to locate a qualied service agent in your area. POSSIBLE CAUSES - CHECK/REP AIR DISPLA YED F AUL T/ALERT MESSAGE The water heater ’s control system is polarity sensitive and will lock • out and disable heating op[...]

55 F AUL T AND ALERT MESSAGES (CONT) Call the technical support phone number listed on the back cover for further technical assistance or to locate a qualied service agent in your area. POSSIBLE CAUSES - CHECK/REP AIR DISPLA YED F AUL T/ALERT MESSAGE The control system has detected the Blower Prover Switch • contacts are closed when they shoul[...]

56 NOTES[...]

57 NOTES[...]

58 NOTES[...]

59 Limited W arranty State W ater Heaters, the warrantor , extends the following LIMITED WARRANTY to the owner of this water heater . THE T ANK 1. If the glass-lined tank in this water heater shall prove upon examination by the warrantor to have leaked due to natural corrosion from potable water therein, during the rst THREE years after initial [...]

500 T ennessee W altz Parkway , Ashland City , TN 37015 Phone: 800-527-1953 Fax: 800-433-2515 www .statewaterheaters.com[...]