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State Industries SHE50-100PE manual

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Table of contents for the manual

  • Page 1

    1 PRINTED 0308 198148-000 COMMERCIAL / RESIDENTIAL GAS W A TER HEA TERS FOR MODELS:  • SHE50-100NE  • SHE50-100PE  • GP650 YTPDT  • GP650HTPDT SER VICE HANDBOOK UL TRA HIGHEFFICIENCY POWERVENT/POWERDIRECTVENT[...]

  • Page 2

    ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT V ENT SERVICE MANUAL Technica l Literature Department ©2008 T ABLE OF CONTENT S INTRODUCTION ................ ................ ............. ............... 2 Qualifications ................ ................ ............. ............... 2 Service Warning .............. ................. ............. [...]

  • Page 3

    ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL Technical Literature Dep artment 2 of 52 Ashland City, TN © 2008 Servicing shou ld on ly be perfo rm e d by a Qua lified Ser vice Agen t INTRODUCTION This Service Manual is designed to be an aid in servicing and trou bleshooting the 96% thermally efficient, 50 gallon, 100,000 Bt[...]

  • Page 4

    Technical Literature Department 3 of 52 Ash l and City, TN © 2008 Servicing sh ould only be performed by a Qualified S ervice Agent ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL INSTRUCTION MANUAL Have a copy of the Instructi on Manual that came with the water heat er on hand for the correct model water heat er you are work[...]

  • Page 5

    ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL Technical Literature Dep artment 4 of 52 Ashland City, TN © 2008 Servicing shou ld on ly be perfo rm e d by a Qua lified Ser vice Agen t INST ALLATION CONSIDERATIONS INSTRUCTION MANUAL Installation inform ation given in th is Service Manual is not a complete installation instruc[...]

  • Page 6

    Technical Literature Department 5 of 52 Ash l and City, TN © 2008 Servicing sh ould only be performed by a Qualified S ervice Agent ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL AIR REQUIREMENT S Carefully review the requirem ents for combustion and ventilation air in the Instruction Manual that came with the water heater .[...]

  • Page 7

    ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL Technical Literature Dep artment 6 of 52 Ashland City, TN © 2008 Servicing shou ld on ly be perfo rm e d by a Qua lified Ser vice Agen t VE N T I N G The venting information presented in this Service Manual is not a complete venting installation instruction. Refer to the Instruc[...]

  • Page 8

    Technical Literature Department 7 of 52 Ash l and City, TN © 2008 Servicing sh ould only be performed by a Qualified S ervice Agent ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL V ENTING (CONT) Pipe Size Requirement s Ensure the correct size pipe has been used for the overall equivalent length of the vent and intake air pip[...]

  • Page 9

    ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL Technical Literature Dep artment 8 of 52 Ashland City, TN © 2008 Servicing shou ld on ly be perfo rm e d by a Qua lified Ser vice Agen t ELECTRICAL REQUIREMENT S The water heater covered by this Service Manual must be grounded in accordance with the local codes, or in the absenc[...]

  • Page 10

    Technical Literature Department 9 of 52 Ash l and City, TN © 2008 Servicing sh ould only be performed by a Qualified S ervice Agent ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL OPERATION & SERVICE HOW IT W ORKS This section of the Service Manual will cover operation, common service procedures and water heater construct[...]

  • Page 11

    ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL Technical Literature Dep artment 10 of 52 Ashland City, TN © 2008 Servicing shou ld on ly be perfo rm e d by a Qua lified Ser vice Agen t BLOWER The blower is an assembly consisting of the blower housing, motor and an integrated VFD (variable frequency drive) . Blower operation [...]

  • Page 12

    Technical Literature Department 11 of 52 Ashland City, TN © 2008 Servicing sh ould only be performed by a Qualified S ervice Agent ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL BURNER The images below show a complete blower/bur ner assembly removed along with a top view of the water heat er with the bl ower removed. Service[...]

  • Page 13

    ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL Technical Literature Dep artment 12 of 52 Ashland City, TN © 2008 Servicing shou ld on ly be perfo rm e d by a Qua lified Ser vice Agen t BURNER (CONT) Burner & Blower Removal The burner should be removed and inspected whenever servic e is being performed for rough operation[...]

  • Page 14

    Technical Literature Department 13 of 52 Ashland City, TN © 2008 Servicing sh ould only be performed by a Qualified S ervice Agent ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL BURNER (CONT) Burner/Blower Removal (cont) Service Notes - Blower Fla nge & Blower Adapter Gasket s. Whenever the blower or burner is removed fo[...]

  • Page 15

    ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL Technical Literature Dep artment 14 of 52 Ashland City, TN © 2008 Servicing shou ld on ly be perfo rm e d by a Qua lified Ser vice Agen t V ENTURI A V enturi is connected to the inlet of the blow er . All combustion air flows through the V enturi. The outlet of the 24 V AC gas v[...]

  • Page 16

    Technical Literature Department 15 of 52 Ashland City, TN © 2008 Servicing sh ould only be performed by a Qualified S ervice Agent ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL GAS V ALVE The outlet of the gas valve is connected by fla nge directly to the side of the V enturi (page 14). There is no manifold gas line on the [...]

  • Page 17

    ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL Technical Literature Dep artment 16 of 52 Ashland City, TN © 2008 Servicing shou ld on ly be perfo rm e d by a Qua lified Ser vice Agen t GAS PRESSURE T ESTING The water heater covered in this Service Manual is rated at 100,000 Btu/hr input. It is certified for elevations up to [...]

  • Page 18

    Technical Literature Department 17 of 52 Ashland City, TN © 2008 Servicing sh ould only be performed by a Qualified S ervice Agent ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL GAS PRESSURES (CONT) Service Notes - Gas Pressure Adjustment Manifold gas pressure is factor y set and should not be adjusted in the fiel d. If mani[...]

  • Page 19

    ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL Technical Literature Dep artment 18 of 52 Ashland City, TN © 2008 Servicing shou ld on ly be perfo rm e d by a Qua lified Ser vice Agen t AIR PRESSURE SWITCHES Air pressure switch technical bulletins TB-A023-06 and TB-S023-06 ex plain air pressure switch construction and test pr[...]

  • Page 20

    Technical Literature Department 19 of 52 Ashland City, TN © 2008 Servicing shou ld only be per formed by a Qualified Service Ag ent ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL AIR PRESSURE SWITCHES (CONT) The water heater cove red in this Service Manual is factor y equipped with three air pressu re switches. These switche[...]

  • Page 21

    ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL Technical Literature Dep artment 20 of 52 Ashland City, TN © 2008 Servicing should on ly be perfo rm e d by a Qua lified Ser vice Agen t AIR PRESSURE SWITCH OPERATION The control system monitors the “st ate” of the air pressure switches individually through three separate ci[...]

  • Page 22

    Technical Literature Department 21 of 52 Ashland City, TN © 2008 Servicing shou ld only be per formed by a Qualified Service Ag ent ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL AIR PRESSURE SWITCH T ESTING Air pressure switch testin g involves three procedures: • Normal S tate T est • Operational S tate T est • Press[...]

  • Page 23

    ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL Technical Literature Dep artment 22 of 52 Ashland City, TN © 2008 Servicing should on ly be perfo rm e d by a Qua lified Ser vice Agen t AIR PRESSURE SWITCH T ESTING (CONT) Pressure T est The Pressure T est is necessary when the air pressure switch in question has passed the Nor[...]

  • Page 24

    Technical Literature Department 23 of 52 Ashland City, TN © 2008 Servicing shou ld only be per formed by a Qualified Service Ag ent ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL AIR PRESSURE SWITCH T ESTING (CONT) BLOWER PROVER SWITCH PRESSURE TEST BLOCKED INT AKE SWITCH PRESSURE TEST BLOCKED EXHAUST SWITCH PRESSURE TEST[...]

  • Page 25

    ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL Technical Literature Dep artment 24 of 52 Ashland City, TN © 2008 Servicing should on ly be perfo rm e d by a Qua lified Ser vice Agen t FLAME SENSING T EST T o prove burner flame during i gnition the control system moni tors flame sensing current through the flame s ensor . It [...]

  • Page 26

    Technical Literature Department 25 of 52 Ashland City, TN © 2008 Servicing shou ld only be per formed by a Qualified Service Ag ent ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL IGNITER CURRENT T EST The water heater covered by th is Service Manual uses a hot surface igniter (HSI). The control system CCB (page 35) pow ers t[...]

  • Page 27

    ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL Technical Literature Dep artment 26 of 52 Ashland City, TN © 2008 Servicing should on ly be perfo rm e d by a Qua lified Ser vice Agen t CONTROL SYSTEM INTRODUCTION This portion of the service manual will cover the control system. The c ontrol system includes several components:[...]

  • Page 28

    Technical Literature Department 27 of 52 Ashland City, TN © 2008 Servicing shou ld only be per formed by a Qualified Service Ag ent ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL UIM The UIM (User Interface Module) is the display on the fron t of the water heater . The UIM’s major components include a Circuit Board with LC[...]

  • Page 29

    ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL Technical Literature Dep artment 28 of 52 Ashland City, TN © 2008 Servicing should on ly be perfo rm e d by a Qua lified Ser vice Agen t UIM (CONT) User input buttons on the UIM include an Up, a Down, and three Operational buttons. The Up and Down buttons ar e used to navigate t[...]

  • Page 30

    Technical Literature Department 29 of 52 Ashland City, TN © 2008 Servicing shou ld only be per formed by a Qualified Service Ag ent ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL UIM (CONT) Desktop Screen The Desktop screen is the defaul t screen. If there are no acti ve fault messages the display will return to this screen [...]

  • Page 31

    ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL Technical Literature Dep artment 30 of 52 Ashland City, TN © 2008 Servicing should on ly be perfo rm e d by a Qua lified Ser vice Agen t UIM (CONT) T able 4 - St atus Icons ST ATUS ICON DESCRIPTION The temperature of the water in the tank has fallen and the wa ter heater will no[...]

  • Page 32

    Technical Literature Department 31 of 52 Ashland City, TN © 2008 Servicing shou ld only be per formed by a Qualified Service Ag ent ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL UIM (CONT) T able 5 - Operational St ates (Modes) STAT E DESCRIPTION S tandby The water he ater is not in an active hea ting cycle. T his usually m[...]

  • Page 33

    ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL Technical Literature Dep artment 32 of 52 Ashland City, TN © 2008 Servicing should on ly be perfo rm e d by a Qua lified Ser vice Agen t OPERATING SET PO INT ADJUSTMENT When the temperature sensed by the control system at the T emperature Probe (top of the water heater) reaches [...]

  • Page 34

    Technical Literature Department 33 of 52 Ashland City, TN © 2008 Servicing shou ld only be per formed by a Qualified Service Ag ent ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL CONTROL SYSTEM MENUS Desktop: This is the default screen fo r the control system. If there are no active faults or warnings the display will retu r[...]

  • Page 35

    ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL Technical Literature Dep artment 34 of 52 Ashland City, TN © 2008 Servicing should on ly be perfo rm e d by a Qua lified Ser vice Agen t CONTROL SYSTEM MENUS (CONT) Heater Information: This menu contains hi storic operational and conf iguration information. Information/settings [...]

  • Page 36

    Technical Literature Department 35 of 52 Ashland City, TN © 2008 Servicing shou ld only be per formed by a Qualified Service Ag ent ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL CCB The CCB circuit board is the main control. All instruct ions for igniti on and temperature control originate from this circuit board. Diagnosti[...]

  • Page 37

    ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL Technical Literature Dep artment 36 of 52 Ashland City, TN © 2008 Servicing should on ly be perfo rm e d by a Qua lified Ser vice Agen t CCB (CONT) Socket Identification All wiring connections and so ckets will be identified in the following p ages. The T roubleshooting section [...]

  • Page 38

    Technical Literature Department 37 of 52 Ashland City, TN © 2008 Servicing shou ld only be per formed by a Qualified Service Ag ent ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL CCB (CONT) J1 Socket - T ransformer J2 Socket - 120 V AC T o Blower J3 Socket - 120 V AC Power Supply J4 Flame Sensor - Male Sp ade Connector J5 So[...]

  • Page 39

    ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL Technical Literature Dep artment 38 of 52 Ashland City, TN © 2008 Servicing should on ly be perfo rm e d by a Qua lified Ser vice Agen t CCB (CONT) J7 Socket - T emperature Probe/ECO (immers ion probe - top of the water heater) J9 Port - Communicatio n Port - Not Used J10 Socket[...]

  • Page 40

    Technical Literature Department 39 of 52 Ashland City, TN © 2008 Servicing shou ld only be per formed by a Qualified Service Ag ent ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL WIRING DIAGRAM Service Notes - Polarity & Ground This water heater is polarity and ground sensitive . The control system will lock out and disp[...]

  • Page 41

    ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL Technical Literature Dep artment 40 of 52 Ashland City, TN © 2008 Servicing should on ly be perfo rm e d by a Qua lified Ser vice Agen t SEQUENCE OF OPERATION Call for heat initiated Air Pre ssu re Switc h Tes t Is Per formed Blower Prover Switch is verified open Blocked Intake [...]

  • Page 42

    Technical Literature Department 41 of 52 Ashland City, TN © 2008 Servicing sh ould only be per formed by a Qualified Service Agent ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL T ROUBLESHOOTING The control system performs exhaustive self diagnostics and displays detected fault conditions in plain english faul t messages on [...]

  • Page 43

    ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL Technical Literature Dep artment 42 of 52 As hland City, TN © 2008 Servicing should on ly be perf orm e d by a Qualified Service Agent CONTROL SYSTEM UNRESPONSIVE DISPLAYED MESSAGE CONDITION/INDICA TES CHECK/REPAIR UIM Display Is Blank On/Off is turned off W ater heater is no t [...]

  • Page 44

    Technical Literature Department 43 of 52 Ashland City, TN © 2008 Servicing sh ould only be per formed by a Qualified Service Agent ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL FAULT MESSAGES DISPLAYED MESSAGE CONDITION/INDICATES CHEC K/REPAIR “AC Reversed” The control system has dete cted the power supply polarity is r[...]

  • Page 45

    ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL Technical Literature Dep artment 44 of 52 As hland City, TN © 2008 Servicing should on ly be perf orm e d by a Qualified Service Agent FAULT MESSAGES (CONT) DISPLAYED MESSAGE CONDITION/INDICA TES CHECK/REPAIR “Upper Probe Short” The control system has de tect ed less than 39[...]

  • Page 46

    Technical Literature Department 45 of 52 Ashland City, TN © 2008 Servicing sh ould only be per formed by a Qualified Service Agent ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL FAULT MESSAGES (CONT) DISPLAYED MESSAGE CONDITION/INDICATES CHEC K/REPAIR “Flame Detect Error” The control system has de tect ed flame sensing c[...]

  • Page 47

    ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL Technical Literature Dep artment 46 of 52 As hland City, TN © 2008 Servicing should on ly be perf orm e d by a Qualified Service Agent FAULT MESSAGES (CONT) DISPLAYED MESSAGE CONDITION/INDICA TES CHECK/REPAIR “Blocked Inlet” The control system has detected open contacts at t[...]

  • Page 48

    Technical Literature Department 47 of 52 Ashland City, TN © 2008 Servicing sh ould only be per formed by a Qualified Service Agent ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL FAULT MESSAGES (CONT) DISPLAYED MESSAGE CONDITION/INDICATES CHEC K/REPAIR “Blocked Exhaust V ent” The control system has detected open contacts [...]

  • Page 49

    ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL Technical Literature Dep artment 48 of 52 As hland City, TN © 2008 Servicing should on ly be perf orm e d by a Qualified Service Agent FAULT MESSAGES (CONT) DISPLAYED MESSAGE CONDITION/INDICA TES CHECK/REPAIR “Blower Prover Open” (Blower Not Running) The control system has d[...]

  • Page 50

    Technical Literature Department 49 of 52 Ashland City, TN © 2008 Servicing sh ould only be per formed by a Qualified Service Agent ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL FAULT MESSAGES (CONT) DISPLAYED MESSAGE CONDITION/INDICATES CHEC K/REPAIR “Low Igniter Current” The control system has dete ct ed less than 2.0 [...]

  • Page 51

    ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL Technical Literature Dep artment 50 of 52 As hland City, TN © 2008 Servicing should on ly be perf orm e d by a Qualified Service Agent FAULT MESSAGES (CONT) DISPLAYED MESSAGE CONDITION/INDICA TES CHECK/REPAIR “Ignition Failure” The control system has dete ct ed less than 1.0[...]

  • Page 52

    Technical Literature Department 51 of 52 Ashland City, TN © 2008 Servicing sh ould only be per formed by a Qualified Service Agent ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL FAULT MESSAGES (CONT) DISPLAYED MESSAGE CONDITION/INDICATES CHEC K/REPAIR “Ignition Failure” The control system has dete ct ed less than 1.0 µA[...]

  • Page 53

    ULTRA HIGH EFFICIENCY POW ER VENT/POWER DIRECT V ENT - SERVICE MANUAL Technical Literature Dep artment 52 of 52 As hland City, TN © 2008 Servicing should on ly be perf orm e d by a Qualified Service Agent FAULT MESSAGES (CONT) DISPLAYED MESSAGE CONDITION/INDICA TES CHECK/REPAIR “Gas V alve Failure” The control system has no t detected any curr[...]

  • Page 54

    2 500T ennesseeW altzParkway AshlandCity ,TN37015[...]