State Industries STC-080 manual

SERVICE HANDBOOK FOR STANDARD RESIDENTIAL GAS WATER HEATERS (NON POWER VENTED MODELS) Printed in the USA 0604 Part Number STC-080 $15.00 This service handbook addresses service issues associated with Standard Residential Gas Water Heaters. Includes C-3 Flammable Vapor Technology.[...]

RESIDENTIAL GAS, NON POWE R VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 1 TABLE OF CONTENTS Page Introduction Terms ......................................................... 1 Tools .......................................................... 2 Residential Gas Water Heaters Guideline[...]

RESIDENTIAL GAS, NON POWE R VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 2 Tools Required:  Phillips head screw driver  3/8, 7/16, ¾ inch open end wrenches  3/16 inch Allen wrench  11/16 inch – 6 point – socket – for anode removal  set of marked drill bits  [...]

RESIDENTIAL GAS, NON POWE R VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 3 Water Hammer – is a concussion of moving water against the sides of a containing pipe or vessel on a sudden stoppage of flow. EX: 1/2 “copper pipe, 5GPM flow (7.2ft/sec.) – stop. Pressure rise of approx[...]

RESIDENTIAL GAS, NON POWE R VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 4 Centimeters = Inches X 2.54 MM (millimeters) = Inches X 25.4 Meters = Inches X .0254 Doubling the diameter of a pipe will increase it s flow capacity (approximately) 5.3 times. CONSTRUCTION: Tank is construct[...]

RESIDENTIAL GAS, NON POWE R VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 5 INSTALLATION OF RESIDENTIAL GAS WATER HEATER Exhaust Vent to Outside of Building Union See Manual and Labels For Installation Clearances Temperature And Pressure Relief Valve – Do Not Reuse Old Valve. Expan[...]

RESIDENTIAL GAS, NON POWE R VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 6 RESIDENTAL GAS WATER HEATER SERVICE This portion of this manual applies to the Operations and Servicing of Residential Gas, Tank Type, Water Heaters, which are vented atmospherically and use a thermocouple as[...]

RESIDENTIAL GAS, NON POWE R VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 7 Residential Gas – continued Burner: The burner assembly consists of the main burner, main burner orifice, main burner gas supply tube, pilot burner, pilot burner orifice, pilot burner gas supply tube and th[...]

RESIDENTIAL GAS, NON POWE R VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 8 Residential Gas – continued Temperature: Two metal probes mounted onto the back of the control are immersed inside the tank water. One probe (the shorter) acts as a temperature high limit. If water gets exc[...]

RESIDENTIAL GAS, NON POWE R VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 9 Residential Gas - continued Water Flow: When a hot water faucet is opened, water pressure from the well tank or street main forces cold water into the water heater. This pushes hot water out of the tank. Oper[...]

RESIDENTIAL GAS, NON POWE R VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 10 Residential Gas - continued Service: Air: A gas burning appliance requires the oxygen contained in 12.5 cubic feet of air (at sea level) for every 1000 BTU of heat that is generated. If your water heater has[...]

RESIDENTIAL GAS, NON POWE R VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 11  Possible carbon monoxide  Smell of burnt gas in the room Residential Gas – continued The instruction manual gives guidelines under “Air Requirements” and “Unconfined “ or “Confined Space?[...]

RESIDENTIAL GAS, NON POWE R VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 12 Residential Gas - continued Sooting causes : If … … then the burner is clean but the chamber and/or flue are sooted check for lack of supply air. the main burner, chamber and flue are sooted check the fo[...]

RESIDENTIAL GAS, NON POWE R VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 13 Residential Gas - continued Electrical Testing– continued Millivolt dropout test through copper magnet winding and ECO (Emergency Cut Off) Procedure : Move meter probe to upper ECO solder joint and ground [...]

RESIDENTIAL GAS, NON POWE R VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 14 Residential Gas – continued Condensation is a mild acid – it will corrode steel Condensation is usually noted when:  water dripping is heard (only) while the main burner is on,  there is “water?[...]

RESIDENTIAL GAS, NON POWE R VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 15 Residential Gas – continued Exhaust Venting Notes Follow current National Fuel Gas Code requirements for proper installation. “D” – Typically, same or larger diameter as Draft Hood outlet “L” –[...]

RESIDENTIAL GAS, NON POWE R VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 16 IMPLEMENTATION CATEGORY ANTICIPATED INTRODUCTION CLASS OF PRODUCTS INCLUDED IN THIS CATEGORY Phase I July 1, 2003 (July 1, 2004* Can.) 30, 40, and 50 gallon atmospheric vented. (Manufactured housing models a[...]

RESIDENTIAL GAS, NON POWE R VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 17 FLAME ARRESTOR Made from Corderite, a fireproof ceramic material, the flame arrestor is built into the base of the water heater. Combustion air is drawn in through the LDO screen (s). After entering the bott[...]

RESIDENTIAL GAS, NON POWE R VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 18 If there has been a flammable vapor ignition, a qualified service agent needs to inspect the arrestor for cracks. The arrestor is not a replaceable part – the heater would need to be replaced. Possible ser[...]

RESIDENTIAL GAS, NON POWE R VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 19 SERVICE: There is no routine service associated with the TCO. The standard thermocouple millivolt output checks described in this service handbook sti ll apply. Millivolt readings indicate that the TCO is cl[...]

RESIDENTIAL GAS, NON POWE R VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 20 To replace a pilot assembly: 1. Turn off the gas supply 2. Disconnect the piezo cable from the piezo button (connection near gas co ntrol valve). 3. Disconnect the pilot tubing, thermocouple and main burner [...]

RESIDENTIAL GAS, NON POWE R VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 21 The three seals on the inner door should be check ed every time any service is performed. The sight glass should be checked to insure it is not damaged or missing. Th e pilot tube and thermocouple routing sh[...]

RESIDENTIAL GAS, NON POWE R VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 22 PIEZO IGNITER C3 TECHNOLOGY models will feature a Piezo igniter to light the pilot burner. The push button switch will be located on the top of the gas control valve. There will be a pl ug connector between [...]

RESIDENTIAL GAS, NON POWE R VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 23 WHY WATER HEATER TANKS LEAK WHAT WHY PREVENTION Water Pressure Water expands when it is heated (Thermal Expansion). Water cannot be compressed. Excessive Pressure in the tank causes failure of joints, welds [...]

RESIDENTIAL GAS, NON POWE R VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 24 WHY WATER HEATER TANKS LE AK - Continued WATER CONDITIONS WHAT WHY PREVENTION “Hard” Water “Hard” water contains minerals. As water is heated the minerals separate from the water and attach to hot su[...]

RESIDENTIAL GAS, NON POWE R VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 25 TECHNICAL BULLETIN - 11 WATER HAMMER GENERAL Water hammer is the destructive forces, poundi ng noises and vibration in a pipin g system when water flowing through a pi peline is stopped abruptly. When water [...]

RESIDENTIAL GAS, NON POWE R VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 26 TECHNICAL BULLETIN - 13 MINERAL BUILD-UP SYMPTOMS  Rumbling  Crackling  Popping CAUSE With the advent of high input and larger stora ge tan ks in both commercial and residential heaters, delimin g h[...]

RESIDENTIAL GAS, NON POWE R VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 27 TECHNICAL BULLETIN - 14 ALUMINUM HYDROXIDE SYMPTOMS “Crackling”, “gurgling”, or “poppi ng” noises from new water heaters (installed less than six months). CAUSE In a few isolated parts of the Uni[...]

RESIDENTIAL GAS, NON POWE R VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 28 TECHNICAL BULLETIN - 21 DISCOLORED WATER SYMPTOMS Rusty, brown, black, or yellow water appearin g in the hot water. CAUSE Complaints of discolored water are commonly blame d on water heaters and storage tank[...]

RESIDENTIAL GAS, NON POWE R VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 29 TECHNICAL BULLETIN - 22 SMELLY WATER CAUSE The most common cause of “smelly wa ter” is a non-toxic sulfate redu cing bacteria, scientifically termed Divibri o Sulfurcan s . This bacterium often enters th[...]

RESIDENTIAL GAS, NON POWE R VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 30 TECHNICAL BULLETIN - 23 CHLORINATION PROCEDURE CAUSE The chlorination pro ce du re is used to eliminate various bacteria tha t accumulate and grow in water heaters. These bacteria often cause odorous or disc[...]

RESIDENTIAL GAS, NON POWE R VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 31 TECHNICAL BULLETIN - 35 NOT ENOUGH HOT WATER - GAS CAUSE Not enough hot water complaints a re becoming more frequent in the water heater industry. This increase was trigge red when changes required by our re[...]

RESIDENTIAL GAS, NON POWE R VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 32 TECHNICAL BULLETIN - 45 THERMAL EXPANSION SYMPTOMS  Effects are only noticeable after hot wate r use followed by perio ds of no water use.  Relief valve drips during any recovery cycle when n o hot or [...]

RESIDENTIAL GAS, NON POWE R VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 33 THE FIX The ideal fix involves the use of a pressu re reducing valve if supply pressures a re above 60 to 70 psi, and a properly sized expan sion tank. The PRV reduce s su pply pressures to 40 to 60 psi allo[...]

RESIDENTIAL GAS, NON POWE R VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 34 TECHNICAL BULLETIN - 52 LEAKING TEMPERATURE AND PRESSURE RELIEF VALVE SYMPTOMS  Water seeping around the relief valve tank conn ection  Leakage at the threaded portion of the relief valve co nne ction [...]

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