State Industries Green Choice manual

1 Instruction Manual PRINTED 1 0 05 183774-001 KEEP THIS MANUAL IN THE POCKET ON HEA TER FOR FUTURE REFERENCE WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED. NOT FOR USE IN MANUF ACTURED (MOBILE) HOMES ALL TECHNICAL AND W ARRANTY QUESTIONS: SHOULD BE DIRECTED T O THE LOCAL DEALER FROM WHOM THE W A TER HEA TER WAS PURCHASED. IF YOU ARE UNSUC[...]

2 SAFE INST ALLA TION, USE AND SER VICE Y our safety and the safety of others is extremely import ant in the inst allation, use and servicing of this water heater . 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 safet[...]

3 GENERAL SAFETY[...]

4 SAFE INST ALLA TION, USE AND SER VICE ............................... 2 GENERAL SAFETY .................................................................. 3 T ABLE OF CONTENTS .............................................................. 4 INTRODUCTION ........................................................................ 4 Preparing for the Ne[...]

5 TYPICAL INST ALLA TION GET T O KNOW YOUR W A TER HEA TER - GAS MODELS A V ent Assembly B Flue Outlet C Anode D Hot Water Outlet E Outlet F Insulation G Gas Supply H Manual Gas Shut-off Valve * INST ALL IN ACCORDANCE WITH LOCAL CODES. * DRIP LEG AS REQUIRED BY LOCAL CODES. FIGURE 1. I Ground Joint Union J Drip Leg (Sediment T rap) K Inner Door L O[...]

6 Thi s a ppli anc e has been de s ign cer t ified as co m plying with A m e ri c a n N a t ion al Standar d /CS A Sta nda rd for water heaters and is cons idered s ui t able for: W ater (Potable) Heating: All models are “considered suitable for water (potable) heating.” Water (Potable) Heating and Space Heating: Certain models are “considere[...]

7 FACTS T O CONSIDER ABOUT THE LOCA TION Carefully choose an indoor location for the new water heater , because the placement is a very important consideration for the safety of the occupants in the building and for the most economical use of the appliance. This water heater is not for use in manufactured (mobile) homes or outdoor installation. Whe[...]

8 Also, the water heater must be located and/or protected so it is not subject to physical damage by a moving vehicle. This water heater must not be installed directly on carpeting. Carpeting m u s t be protected by metal or wood panel beneath the appliance extending beyond the full width and depth of the appliance by at least 3 inches (7.62 cm) in[...]

9 FIGURE 5. FIGURE 8. Optional Wire Grill When the water heater vent cap is low enough to be touched accidentally , or is accessible to small children, installation of a protective vent cover is recommended. See Figure 9. Some local codes may require a vent cap cover . Figure 9 shows the optional wire vent cap protector available from the water hea[...]

10 V ertical Height (Extension Kit) It is simple to determine which kit is needed for vertical height. T ake the total height (to the top of the flue) required and comparing that to “F dimension” in the chart #1, it can be determined which kit needs to be used vertically . FIGURE 1 1. FIGURE 12. CHART # 1 . BTU’s DIMENSION “F” (IN INCHES)[...]

11 ALL INST ALLA TIONS For ease of assembly the installation of the various kit combinations has been broken into individual sections. The two steps below are common to all installations. Once these have been performed, you need only to refer to the type installation that pertains to you. Installation Using V ent Kits: 1. S tandard V ent Kit 900068[...]

12 4. First remove the 3” (76 mm) horizontal extension from the elbow . Start- ing with the long end (with four securing holes), place the 6” (152 mm) diameter vent elbow over the 3” (76 mm) diameter elbow . Bend the round end “oval” to fit the flared oval end of the jacket top. FIGURE 18. 5. Making sure the 6” (152 mm) diameter elbow i[...]

13 1 1. Install the vent collar assembly through the wall, connecting it to the extension and/or elbow (depending on which one was used). FIGURE 25. 12. We have supplied four wood screws to temporarily attach the collar to the exterior wall of the building. However , other types of screws may have to be substituted depending on the material used in[...]

14 Optional V ertical V ent Kit with Standard Horizont al V ent Kit - Installation #2 Any Optional V ent Kit *Each part is stamped with a p art number. The opening through the wall should be cut at this time. If this has not been done, refer to “Cutting The Opening Through The Out side W all,” on p age 1 1. 1. First it must be determined how fa[...]

15 7. Place the 3” (76 mm) elbow on the flue extension. NOTE: Make sure elbow is properly aligned to opening in the outside wall. Mark the 3” (76 mm) diameter end of the flue extension at the slots in the elbow . Using a # 22 drill bit, drill holes into the flue extension at the two slots and secure the elbow to the flue extension using the scr[...]

16 14. Install the vent collar assembly through the wall, connecting it to the extension and /or elbow depending on which one was used. FIGURE 45. 15. Four wood screws are supplied to temporarily attach the collar to the exterior wall of the building. However , other types of screws may have to be substituted depending on the construction material [...]

17 Optional Horizontal V ent Kit - Inst allation #3 If the vent hole has not been cut, refer to “Cutting The Opening Through The Outside W all.” See page 1 1. 1. Lock the elbow to the straight 3” (76 mm) flue pipe. Set this assembly in place on the end of the water heater’s flue collar. FIGURE 52. 2. Mark the flue collar at the slots in the[...]

18 7. Place the waterheater at the opening in the wall at the predetermined clearance. FIGURE 58. 8. Slide the 6” (152 mm) telescoping vent section apart to expose the beads. Use the supplied tube of sealant and fill the exposed beads. FIGURE 59. 9. In ser t the 6 ” ( 1 52 mm) telescoping vent section into the opening in the wall. FIGURE 60. 10[...]

19 16. Collapse the 6” flue extension assembly as shown below . Install the O-ring end of the 3” (7.6 cm) extension approximately 1 1/4” (3.2 cm) into the end of the vent cap. If necessary , apply a soap solution to the O-ring to ease the assembly . Rotate the 3 ” extension clockwise until the other end is locked to the studs on the elbow .[...]

20 FIGURE 72. C HART # 4 . *GAL CAP *BTU’s in 1000’ s - NA T ./ L .P . A 4 0 36/36 48 3/4” 124 cm 5 0 38/38 57 1/2” 146 cm 4 0 40/40 48 3/4” 124 cm 5 0 48/44 61” 155 cm 7 5 55 NA T . 63” 160 cm *Check the model and rating plate attached to the water heater for specific model number and other detailed information. 2. Set the ve rtical [...]

21 8. Be sure the 6 ” (15.2 cm) diameter elbow is centered around the 3” (7.6 cm) diameter flue, secure using two sheet metal screws at the connection o f the elbow a nd the 6” ( 1 5 .2 cm) vertical extension. F I GURE 79. 9 . S l i d e the ven t c ol lar (to be i n s ta l l e d later) over the 6” ( 15.2 c m ) vent elbow . FIGURE 80. 10. Mo[...]

22 15. Four wood screws were supplied to temporarily attach the collar to the exterior wall of the building. However, you may have to substitute other types of screws depending on the construction material of the exterior wall. FIGURE 86. 16. Insert the vent cap into the vent collar assembly . FIGURE 87. 17. The vent cap has four holes around the o[...]

23 porcelain- enameled vent cap assembly and th e 6 ” ( 15.2 cm) vent wall assembly shown by Figure 94. FIGURE 94. The water heater model designation on the rating plate will have a suffix “P” to indicate this alternate vent cap assembly . The alternate installation instructions below will replace the itemized instructions in the manual as fo[...]

24 The following alternate illustrated instructions will replace the itemized instructions in the manual as follows: Items 1 1 through 14 on page 18 and Items 14 through 17 on pages 21 and 22. 1 . Making sure the arrow points “up”, install the vent collar assembly through the wall, connecting it to the 6” ( 1 5.2 cm) telescoping extension. Re[...]

25 INST ALLING THE NEW W A TER HEA TER WA TER PIPING HOTTER W A TER CAN SCALD: W ater heaters are intended to produce hot water . W ater heated to a temperature which will satisfy space heating, clothes washing, dish washing, cleaning and other sanitizing needs can scald and permanently injure you upon contact. Some people are more likely to be per[...]

26 Figure 104 shows the typical attachment of the water piping to the water heater . The water heater is equipped with 3/4 inch NPT water connections. NOTE: If using copper tubing, solder tubing to an adapter before attaching the adapter to the cold water inlet connection. Do not solder the cold water supply line directly to the cold water inlet. I[...]

27 If after manually operating the valve, it fails to completely reset and continues to release water , immediately close the cold water inlet to the water heater , follow the draining instructions, and replace the temperature-pressure relief valve with a new one. FIGURE 106. FILLING THE WA TER HEA TER Never use this water heater unless it is compl[...]

28 When installed at elevations above 2,000 feet (610 meters), input rating should be reduced at the rate of 4 percent for each 1,000 feet (305 meters) above sea level which requires replacement of the burner orifice in accordance with National Fuel Gas Code ANSI Z223.1/ NFP A 54. Cont act your local gas supplier for further information. Failure to[...]

29 INST ALLING THE NEW W A TER HEA TER (cont’d.) INST ALLA TION CHECKLI ST BEFORE LIGHTING THE PILOT : 1 . Check the gas line for leaks. a. Use a soapy water solution. DO NOT test for gas leaks using a match or open flame. b. Brush the soapy water solution on all gas pipes, joints and fittings. c. Check for bubbling soap. This means you have a le[...]

30[...]

31 TEMPERA TURE REGULA TION HOT WA TER CAN SCALD: Water heaters are intended to produce hot water . W ater heated to a temperature that will satisfy space heating, clothes washing, dish washing, and other sanitizing needs can scald and permanently injure you upon contact. Some people are more likely to be permanently injured by hot water than other[...]

32 Excessive condensation may be noticed during the winter and early spring months when incoming water temperatures are at their lowest. Good venting is essential for a gas fired water heater to operate properly as well as to carry away products of combustion and water vapor . SMOKE / ODOR It is not uncommon to experience a small amount of smoke an[...]

33 PERIODIC MAINTENANCE VENTING SYSTEM INSPECTION At least once a year a visual inspection should be made of the venting system. Y ou should look for: 1 . Obstructions which could cause improper venting. The combustion and ventilation air flow must not be obstructed. 2 . Damage or deterioration which could cause improper venting or leakage of combu[...]

34 HOUSEKEEPING V acuum around base of water heater for dust, dirt, and lint on a regular basis. INST ALLED IN SUIT ABLE AREA: T o insure sufficient ventilation and combustion air supply , proper clearances from the water heater must be maintained. See “Locating the New Water Heater” section. Combustible materials such as clothing, cleaning mat[...]

35 DRAIN VAL VE WASHER REPLACEMENT (See Figure 1 14) 1 . T urn “OFF” gas supply to water heater. 2 . Follow “Draining” instructions. 3 . Turning counterclockwise ( ), remove the hex cap below the screw handle. 4 . Remove the washer and put the new one in place. 5 . Screw the handle and cap assembly back into the drain valve and retighten us[...]

36 REP AIR P ARTS LIST[...]

37 P ARTS GAL. CAP . 40 50 40 50 75 K EY # DESCRIPTION BTU’ s in 1000’ s NA T/L.P . 36/36 38/38 40/40 48/44 55 N A T . 1. Access Door Clips (Pkg. 2) 9000694 9000694 9000694 9000694 9000694 2. Right Access Door w/Gasket 9000695 9000695 9000695 9000695 9000695 3. Left Access Door w/Gasket 9000696 9000696 9000696 9000696 9000696 4. Burner Orifice [...]

38 REP AIR P ARTS LIST[...]

39 P ARTS GAL. CAP . 4 0 5 0 4 0 50 75 KEY # DESCRIPTION BTU’s in 1000’ s NA T/L.P . 36/36 38/38 40/40 48/44 55 N A T . Kit A VK-2 No. 9001247 32. 3” I.D. x 13 7/8” Flue Extension Pipe with 9001281 9001281 9001281 9001281 9001281 Gaskets 33. 6” O.D. x 13 5/8” V ent Extension Pipe 9001275 9001275 9001275 9001275 9001275 34. 3” O.D. x 1[...]

40 These guidelines should be utilized by a qualified service agent. TROUBLESHOOTING GUIDELINES Problem Cause Solution Improperly sealed, hot or cold supply connection, Tighten threaded connections. relief valve, drain valve, or thermostat threads. Leakage from other appliances or water lines. Inspect other appliances near water heater. Condensatio[...]

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