State Industries GS6 40 YOCT Series 200 manual

1 This water heater complies with ANSI Z21.10.1-current edition regarding the accidental or unintended ignition of fl ammable vapors, such as those emitted by gasoline. For Y our Safety AN ODORANT IS ADDED T O THE GAS USED BY THIS W A TER HEA TER. • Safety Instructions • Installation • Operation FVIR GAS WATER HEATER (FLAMMABLE V APOR IGNITI[...]

2 T ABLE OF CONTENTS W ater Heater Safety .............................................................................................................................. ............................................ 1 -2 Safe Installation, Use and Service ................................................................................................[...]

3 SAFE INST ALLA TION, USE AND SER VICE Y our safety and the safety of others is extremely important in the installation, use and servicing of this water heater . Many safety-related messages and instructions have been provided in this manual and on your water heater to warn you and others of a potential hazard. Read and obey all safety messages an[...]

4 Fire or Explosion Harzard Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. Avoid all ignition sources if you smell Natural or LP gas. Do not expose water heater control to excessive gas pressure. Use only gas shown on rating plate. Maintain required clearances to combustibles. Keep[...]

5 TYPICAL INST ALLA TION GET TO KNOW YOUR W A TER HEA TER - GAS MODELS A V ent Pipe B Draft hood C Anode (Not Shown) D Hot W ater Outlet E Insulation F Gas Supply Piping G Manual Gas Shut-off V alve H Ground Joint Union I Drip Leg (Sediment T rap) J Inner Door K Outer door L Union M Inlet W ater Shut-off V alve N Cold W ater Inlet O Inlet Dip T ube[...]

6 INST ALLING YOUR GAS W A TER HEA TER Important Information About This W ater Heater This gas water heater was manufactured to voluntary safety standards to reduce the likelihood of a flammable vapor ignition incident. New technology used in meeting these standards makes this product more sensitive to installation errors or improper installation e[...]

7 Location Requirements Carbon Monoxide Poisoning Hazard W ARNING Do not install in a mobile home. Doing so can result in carbon monoxide poisoning and death. The FVIR System is designed to reduce the risk of flammable vapor-related fires. The patented system protects your family by trapping the burning vapors within the water heater combustion cha[...]

8 IMPORT ANT : The water heater should be located in an area where leakage of the tank or connections will not result in damage to the area adjacent to the water heater or to lower floors of the structure. Due to the normal corrosive action of water , the tank will eventually leak after an extended period of time. Also any external plumbing leak, i[...]

9 CHECK WITH LOCAL UTILITY FOR MINIMUM HEIGHT 3” MINIMUM DRIP LEG GROUND JOINT UNION SUIT ABLE DRAIN MANUAL GAS SHUT -OFF VAL VE DISCHARGE PIPE (DO NOT PLUG OR CAP) 6” MAXIMUM AIR GAP FIGU RE 3 . Gas Pressure W ARNING Explosion Hazard • Gas leaks can not always be detected by smell. • Gas suppliers recommend that you use a gas detector appr[...]

10 LP Gas Only W ARNING Explosion Hazard Have a qualified person make sure L.P . gas pressure does not exceed 13” water column. Examples of a qualified person include: licensed plumbers, authorized gas company personnel, and authorized service personnel. Failure to do so can result in death, explosion, or fire. Liquefied petroleum gas is over 50%[...]

11 T ABLE 3 BTUH Input Minimum Square Feet with 8’ Ceiling T ypical Room with 8’ Ceiling 30,000 188 9 x 21 45,000 281 14 x 20 60,000 375 15 x 25 75,000 469 15 x 31 90,000 563 20 x 28 105,000 657 20 x 33 120,000 750 25 x 30 135,000 844 28 x 30 IMPORT ANT : • The area must be open and be able to provide the proper air requirements to the water [...]

12 12” MAXIMUM PERMANENT OPENINGS TO T HE OUTSIDE OR ADDITIONAL ROOMS WITHIN THE BUILDING CLOSET OR OTHER CONFINED SPACE 12” MAXIMUM FIG UR E 4. All Air from Inside the Building When additional air is to be provided to the confined area from additional room(s) within the building, the total volume of the room(s) must be of sufficient size to pr[...]

13 ALTERNATIVE OPENING LOCATION 1 SQ. INCH PER 3000 BTUH CONFINED SPACE ALL AIR FROM OUTDOORS - USING A SINGLE PERMANENT OPENING FIGU RE 8 B. V ent Pipe System This water heater uses a non-direct, single-pipe vent system to remove exhaust gases created by the burning of fossil fuels. Air for combustion is taken from the immediate water heater locat[...]

14 Align the legs of the draft hood with the slots provided. Insert the legs and secure the draft hood to the water heater ’s top with the four screws provided as shown in Figure 9. Do not alter the draft hood in any way . If you are replacing an existing water heater , be sure to use the draft hood supplied with this water heater . V ent Pipe Si[...]

15 Piping Installation Piping, fittings, and valves should be installed according to the installation drawing (Figure 13). If the indoor installation area is subject to freezing temperatures, the water piping must be protected by insulation. The water supply pressure should not exceed 80 psi. If this occurs, a pressure reducing valve with a bypass [...]

16 TEMPERA TURE AND PRESSURE (T&P) RELIEF V AL VE (OPTIONAL TOP T&P RELIEF V AL VE NOT SHOWN) DRAIN LINE 3/4” ID MINIMUM DRAIN 1” MINIMUM 6” MAXIMUM AIR GAP MET AL DRAIN P AN DISCHARGE PIPE (DO NOT CAP OR PLUG) MASSACHUSETTS: INST ALL A V ACUUM RELIEF IN COLD W ATER LINE PER SECTION 19 MGL 142. COLD W ATER INLET V AL VE (SHUT -OFF VAL[...]

17 valve or ha ve any reducing co upling installed in th e discharge line. • Must not be c apped, blocked, plugged or contain any valve be t ween the relief valv e and the end of t he dis- char ge l ine. • Must ter minate a max imum of six inches ab ove a floo r drain or exter nal to the building. • Must be c apable of withst anding 250 °F ([...]

18 • Be sure to follow the manual(s ) shipped with the air handler system. • This water heater is not to be used as a replacement for an existing boiler installation. • Do not use with piping t hat has been treated wit h chromates, b oiler seal or other c hemicals and do not add any chemicals to the water heater piping. • If the spac e heat[...]

19 □ F resh air ope nings sized cor rec tly with c onsider ation given to the blocking ef fec t of louvers and grilles. □ Duct wor k is the same c ross - secti onal area as the openings. V ent Pipe System Check for proper drafting at the water heater draft hood. Refer to the “Checking the Draft” section of this manual for the test procedure[...]

20 W ARNING Explosion Hazard Replace view port if glass is missing or damaged. Failure to do so can result in death, explosion or fire. Ligh ti ng In st r uc t ion s Read and understand these directions thoroughly before attempting to light or re-light the pilot. Make sure the view port is not missing or damaged. (See Figure 23) Make sure the tank [...]

21 M ATCH RELIEF OPENIN G DRAFT HOOD FIGU RE 17 . If the flame flutters or is blown out, combustion products are escaping from the relief opening. If this occurs, do not operate the water heater until proper adjustments or repairs are made to the vent pipe system and/or air supply requirements. FOR YOUR SAFETY READ BEFORE LIGHTING TO TURN OFF GAS T[...]

22 Burner Flames Inspect the burner flames through the viewport and compare them to the drawings in Figure 18. A properly operating burner should produce a soft blue flame. Blue tips with yellow inner cones are satisfactory . The tips of the flame may have a slight yellow tint. The flame should not be all yellow or have a sharp blue-orange color . [...]

23 from water damage resulting from normal condensation production, a leaking tank or piping connections. Refer to the “Location Requirements” section. W ater Heater Sounds During the normal operation of the water heater , sounds or noises may be heard. These noises are common and may result from the following: 1 . Nor mal expansion and c ontra[...]

24 Anode Rod/W ater Odor Each water heater contains at least one anode rod, which will slowly deplete while protecting the glass-lined tank from corrosion and prolonging the life of the water heater . Once the anode is depleted, the tank will start to corrode, eventually developing a leak. Certain water conditions will cause a reaction between this[...]

25 properly . T o prevent water damage, the valve must be properly connected to a discharge line which terminates at an adequate drain. Standing clear of the outlet (discharged water may be hot), slowly lift and release the lever handle on the temperature and pressure relief valve to allow the valve to operate freely and return to its closed positi[...]

26 2. Chec k the bur ner to see if it is dir t y or c logge d. The burner may be cleaned with soap and hot water (Figure 24 ). BURNER (BOTTOM VIEW) SCREWS PILOT ASSEMBL Y (BOTTOM VIEW) FIGU RE 24. Replacing the Thermocouple 1 . Remov e the manifold/ bur ner assembly as directed previously . 2. Lift the retainer c lip strai ght up from th e back of [...]

27 10. Reposition the t wo piece wire c onnector in t he manifold door opening and sec ure it with the retainer c lip. 1 1 . Carefully bend the new pilot tube and thermoc ouple to match the bend of the manifo ld tube. NOTE : W hen bending DO NOT crimp or c rease the pilot tube or therm oc ouple. (Figure 25 ) 1 2. Before you proc eed to th e next st[...]

28 tight in the gas control valve/thermostat. Finally , start the thermocouple nut and turn it all the way in by hand. An additional quarter turn with a 3/8” open-end wrench will then be sufficient to seat the lockwasher . When you are finished, connect the two wire leads that go to the thermal switch. 7 . Reconnec t the igniter wire. 8. T urn ga[...]

29 Replacing the Gas V alve: 1 . T o replace t he gas co ntrol valve/ther most at, reassemble in reverse order . When replacing th e gas contro l valve/ thermost at, thread a c or rectly sized pipe into the inlet and use it to turn the gas valve ( clo ck wi se. ) DO NO T OVER TIG HTEN or damage may result. NOTE: Use an appro ved TEFL ON ® tape or [...]

30 PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION HIGH OPERA TION COSTS 1 . Ther most at set too high 2. Sed iment or lime in tank 3. W ater heater too small for j ob 4. W rong piping c onnections 5. Leaking faucets 6. Gas leaks 7 . Wasted hot water 8. Long runs of exposed piping 9. Hot water piping in e xpo sed wall 1 . Set temperature dial to lower [...]

31 PILOT LIGHT TROUBLESHOOTING FLOWCHART Has the thermal switch tripped? NO Check for insufficient combustion air . Are there openings for make-up air to enter the room? Are the openings of sufficient size? See “Combustion Air Supply and Ventilation” section in this manual for requirements. Is there a furnace/air handler in the same room as the[...]

32 REP AIR P ARTS ILLUSTRA TION *Pictured on next page. When ordering repair parts always give the following information: 1. Model, serial, and product number 2. T ype of gas 3. Item number 4. Parts description Repair Parts List LEGEND Special anode rod (see Anode Rod/W ater Odor section) T emperature and Pressure Relief V alve is required, but may[...]

33 Listed Parts Kits and Illustrations It e m 12: Pi l ot / Pilot T ube Assembly kit, which c ontains t he pilot assembly , ther moc ouple, igniter electro de and retainer clip (Natural G as ) Ite m 13: Pilot / Pilot T ube Ass emb ly kit, which co ntains the pilot assembly , ther moc ouple, igniter elect rode and retainer c lip (L.P . Gas ) Item 1 [...]

34 NOTES[...]

35 THIS W ARRANTY IS APPLICABLE T O THE ORIGINAL OWNER ONL Y , in accordance with the warranty terms and conditions specified below . State W ater Heaters (the warrantor) will furnish the ORIGINAL OWNER, 1) a replacement State water heater of equivalent size and current model if the glass-lined tank in this water heater leaks and, 2) a replacement [...]

36 LIMIT A TION ON IMPLIED W ARRANTIES Implied warranties, including any warranty of merchantability imposed on the sale of this heater under state law are limited to one year duration for the heater or any of its parts. Some states do not allow limitations on how long an implied warranty lasts, so the above limitations may not apply to you. CLAIM [...]