State Industries GPX manual

SER VICE HANDBOOK FOR ST ANDARD RESIDENTIAL FVIR GAS W A TER HEA TERS MODELS: GPX, GS6, GSX – SERIES 200/201 GS6, GSX (40-Gallon Short) SERIES 202/203 06/09 316876-000[...]

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3 Y our safety and the safety of others is extremely important in the servicing of this water heater . Many safety- related messages and instructions have been provided in this handbook and on your water heater to warn you and others of a potential hazard. Read and obey all safety messages and instructions throughout this handbook. It is very impor[...]

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 i[...]

PROBLEM POSSIBLE CAUSE TEST / CORRECTIVE ACTION 5 TROUBLESHOOTING QUICK REFERENCE NO HOT W A TER: Insuf fi cient Combustion Air or V enting Issues – combustion chamber thermal cut off tripped. Follow the steps on pp 18 – 19. Always check and clean the base ring fi lter and the fl ame arrestor . Pilot will not light Check gas supply/Bleed air[...]

PROBLEM POSSIBLE CAUSE TEST / CORRECTIVE ACTION 6 W A TER LEAKAGE: Thermostat does not shut-off Check the Gas Control V alve/Thermostat as described on p. 20-21. Drain valve dripping/leaking Back fl ush to clean- out sediment, replace if necessary T ank Leak Check Leakage Checkpoints described on p. 25.[...]

7 T ABLE OF CONTENTS BASIC INST ALLA TION ............................................................................................................ .......................... 8-16 DRAINING AND FILLING THE W A TER HEA TER .................................................................................................. 17 Draining the W ater Heat[...]

8 Exhaust V ent to Ouside of Building Union Union Wa t e r Shut-Off Va l v e W ater Supply- Cold* Expansion T ank Pressurize to Equal Supply W ater Pressure* (Relieve water pressure on the expansion tank before adjusting air pressure.) T emperature-Pressure Relief V alve with discharge piped to an adequate drain. Do not cap or plug. 6” Maximum Ai[...]

9 This portion of this handbook applies to the Operations and Servicing of Residential Gas, T ank T ype, Water Heaters, which are vented atmospherically and use a thermocouple as their electrical source. Control: There are two gas control valve/thermostat con fi gurations available. Both valves have similar control elements such as the Gas Control[...]

10 Burner/Manifold Door Assembly: The burner/manifold assembly consists of several components such as: main burner , burner ori fi ce, manifold tube, pilot burner , pilot ori fi ce, pilot tube, igniter , and thermocouple. See the fi gure below for the complete list of components. The pilot burner remains on once it is manually lit. When incoming[...]

11 Energy Cut Off (ECO): A metal tube (T emperature Probe) mounted onto the back of the gas control valve/thermostat is immersed inside the tank water . The probe acts as a temperature high limit. If water gets excessively hot, an Energy Cut Off (ECO) switch within the probe opens, interrupting the small electrical current to the gas valve, and gas[...]

12 Thermostat Operation: Standard residential water heaters use mechanical thermostats. With a mechanical thermostat, a dial setting of 120° F may shut the burner down at a tank temperature between 1 10° and 130° F . The heater will consistently shut off at this same temperature. For this same reason, water temperature may drop 15° F - 25° F ,[...]

13 BASIC INST ALLA TION & OPERA TION T able 1: 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 th[...]

14 BASIC INST ALLA TION & OPERA TION All Air from Inside the Building: When additional air is to be provided to the con fi ned area from additional room(s) within the building, the total volume of the room(s) must be of suf fi cient size to properly provide the necessary amount of fresh air to the water heater and other gas utilization equipm[...]

15 BASIC INST ALLA TION & OPERA TION V ent Connectors: 1 . T ype B, D ouble wall, U .L. Listed Ven t Pipe. 2. S ingle wall V ent Pipe. Maintain the manufacturer ’s speci fi ed minimum clearance from combustible materials when using type B double wall vent pipe. V ent connectors made of type B, double wall vent pipe material may pass through [...]

16 • The c onnector must be f ir mly att ached and sealed to prev ent it from falling out. • T o aid in removing the c onnector , a thimble or slip joint may be used. • The c onnector must not extend beyond the inner edge of the c himney as it ma y restric t the space between it and the o pposite wall of the chimney LISTED LINED CHIMNEY 2 FT.[...]

17 DRAINING AND FILLING THE W A TER HEA TER D raining the W ater Heater The water heater should be drained if being shut down during freezing temperatures. Also, periodic draining and cleaning of sediment from the tank may be necessary . 1 . T urn of f the gas to the water heater at the manual gas shut-off valve. 2. Open a nearby hot water faucet u[...]

18 CHECKING THE GAS SUPPL Y PRESSURE Checking the Gas Supply Pressure Gas pressure checks are done with flowing gas using a gas pressure gauge capable of reading pressure in inches of water column. • Supply gas pressure chec ks are measured before the gas c ontrol valve/ther mostat and as c lose to the water heater as possible. • Manifold (main[...]

19 CHECKING FOR SUFFICIENT COMBUSTION AIR OR VENTING ISSUES Flue Products V ented to Ouside of Building Draft Hood Dilution Air Air is drawn in for combustion. Keep area clean and free from combustibles and flammable vapors. Dilution Air (Relief Opening) Dilution Air Match Outer Door Draft T est After successfully lighting the water heater , allow [...]

20 TESTING THE THERMOCOUPLE AND GAS CONTROL V AL VE/THERMOST A T Thermocouple Output T est The following test will check the DC voltage generated by the thermocouple when the pilot light is lit. 1 . Disco nnect the ther moc ouple from the gas c ontrol valve/therm ostat as shown in t he adjacent f igure. 2. Using a mult imeter with alligator clips l[...]

21 Removing the Burner from the Manifold/ Burner Assembly Natural Gas (Low Nox) & L.P . Gas Burner 1 . T ake off t he burner by removing the t wo ( 2 ) sc rews loc ated underneath the bur ner . 2. Check the bur ner to see if it is dir t y or cl ogged. The burner may be cleaned w ith soap and hot water . BURNER (BOTTOM VIEW) SCREWS PILOT ASSEMBL[...]

22 OTHER FITTINGS NOT SHOWN FOR CLARITY IGNITER WIRE THERMOCOUPLE TWO PIECE WIRE CONNECTOR RET AINER CLIP PILOT TUBE PILOT BRACKET PILOT MANIFOLD TUBE MANIFOLD/BURNER DOOR OPENING FERRULE NUT Figure 25 Replacing the Manifold/Burner Assembly W ARNING Explosion Hazard • Tighten both manifold door screws securely . • Remove any fiberglass between [...]

23 MANIFOLD TUBE TIP BRACKET SLO T CLOSE-UP INSIDE VIEW OF THE COMBUSTION CHAMBER. Figure 27 Removing and Replacing the Gas Control V alve/Thermostat IMPORT ANT : This water heater has a resettable thermal switch installed. Do not attempt to disable or modify this feature in any way . Use only factory authorized replacement parts. Removing t he Ga [...]

24 ADJUSTING THE TEMPERA TURE ON THE GAS CONTROL V AL VE THERMOST A T W ater temperature over 125°F (52°C) can cause servere 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. T emperature limiting valve[...]

25 GAS W A TER HEA TER SIZING GUIDE Use the following information as a guide to approximate the correct size water heater for the residence: 30 gallon size (21 gallon draw) for one bath residence. • 40 gallon size (28 gallon draw) for two bath residence -or one bath with an automatic clothes washer . • 50 gallon size (35 gallon draw) for three [...]

26 TECHNICAL BULLETINS W A TER HAMMER ..................................................................................................................................................27 MINERAL BUILD-UP .............................................................................................................. ................................28 [...]

27 BULLETIN 1 1 W A TER HAMMER GENERAL W ater hammer is the destructive force, pounding noise and vibration in a piping system when water fl owing through a pipeline is stopped abruptly . When water hammer occurs, a high intensity pressure wave travels back through the piping system until it reaches a point of some relief. The shock wave will then[...]

28 BULLETIN 13 MINERAL BUILD-UP SYMPTOMS • Rumbling • Crackling • Popping CAUSE With the increase in fuel costs and hot water consumption, deliming has become a necessity of modern maintenance. Lime (CaCO3), is the most notable factor when discussing water hardness. Lime is present in every water system to some degree. Since lime is inversely[...]

29 BULLETIN 14 ALUMINUM HYDROXIDE SYMPTOMS “Crackling”, “gurgling”, or “popping” noises from new water heaters (installed less than six months). CAUSE In a few isolated parts of the United States where the water supply has a relatively high pH (8+), water conditions will react with the aluminum anode to form excessive amounts of aluminu[...]

30 BULLETIN 15 CONDENSA TION SYMPTOMS The water heater appears to be releasing water while the main burner is on or water is found surrounding the heater shortly after the water heater has been used. This bulletin explains why fl ue gases condense and how you can dif ferentiate between condensation and leaking. CAUSES Condensate is the result of a[...]

31 BULLETIN 21 DISCOLORED W A TER SYMPTOMS Rusty , brown, black, or yellow water appearing in the hot water . CAUSES Complaints of discolored water are commonly blamed on water heaters and storage tanks, but in fact, it is a rare occurrence for today’s high quality glass lined tanks to have a lining failure signi fi cant enough to allow water to[...]

32 BULLETIN 22 SMELL Y W A TER CAUSES The most common cause of “smelly water” is a non-toxic sulfate reducing bacteria, scienti fi cally termed Divibrio Sulfurcans. This bacteria often enters the water system through construction or a break in ground piping. The bacteria creates the energy it needs to survive by converting sulfate (SO4) to hyd[...]

33 BULLETIN 23 CHLORINA TION PROCEDURE CAUSES The chlorination procedure is used to eliminate various bacteria that accumulate and grow in water heaters. These bacteria often cause odorous or discolored water conditions. PROCEDURE Please read the steps of the chlorination procedure prior to beginning. If you feel uncomfortable performing any of the[...]

34 BULLETIN 35 NOT ENOUGH HOT WA TER - GAS CAUSES Complaints regarding an insuf fi cient supply of hot water are typically the result of a water heater that cannot meet the demands of the residence (both people and appliances). The demand for suf fi cient hot water may also be exceeded if additional people and/or appliances are added to the resid[...]

35 BULLETIN 45 THERMAL EXP ANSION SYMPTOMS • Ef fects are only noticeable after hot water use followed by periods of no water use. • Relief valve drips during any recovery cycle when no hot or cold water is used. • Hot water pipes creak while heater is recovering and all valves are closed. • T anks or other components of the water supply sy[...]

36 THERMAL EXP ANSION THE FIX The ideal fi x involves the use of a pressure reducing valve if supply pressures are above 60 to 70 psi, and a properly sized expansion tank. The PR V reduces supply pressures to 40 to 60 psi allowing an economically priced and sized expansion tank to be used. The PR V also of fers the bene fi t of saving water and p[...]

37 BULLETIN 52 LEAKING TEMPERA TURE AND PRESSURE RELIEF V AL VE SYMPTOMS • W ater seeping around the relief valve tank connection • Leakage at the threaded portion of the relief valve connection • Intermittent weeping and/or dribbling from the relief valve • Large volume of hot water sporadically discharged from the relief valve GENERAL The[...]

38 BULLETIN 60 INSULA TION BLANKETS GENERAL The purpose of an insulation blanket is to reduce the standby heat loss encountered with storage tank heaters. Most modern water heaters have adequate factory installed insulation, the use of an after market insulation blanket is no longer recommended by most experts. While the use of an external insulati[...]

39 Draw efficiency is the quantity of hot water available to the consumer before the outlet water temperature decreases 25 degrees F . A 40 gallon water heater will typically provide 70% (28 gallons) of this “usable” hot water (60% is the minimum). The burner or elements are allowed to operate during this test. Incoming, cold water mixes the re[...]

40 One pound of gas pressure is equal to 27.7 inches water column pressure Inches of W ater Column X .036091 = PSI Inches of W ater Column X .073483 = Inches of Mercury (Hg.) Centimeters = Inches X 2.54 MM (millimeters) =Inches X 25.4 Meters = Inches X .0254 Doubling the diameter of a pipe will increase its flow capacity (approximately) 5.3 times. [...]

41 NOTES[...]

42 NOTES[...]

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44 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 UNSUCCESSFUL, CONT ACT ST A TE W A TER HEA TERS RESIDENTIAL TECHNICAL ASSIST ANCE 1-800-365-0024 OR WWW .S T A T E WA TERHEA TERS.COM.[...]