Installation Instructions and Use & Care Guide RESIDENTIAL GAS WATER HEATERS FVIR GAS WATER HEATER (FLAMMABLE VAPOR IGNITION RESISTANT) FOR POTABLE WATER HEATING ONLY. NOT FOR USE IN MOBILE HOMES. This water heater complies with ANSI Z21.10.1-current edition regarding the accidental or unintended ignition of flammable vapors, such as those emitted by gasoline. For Your Safety AN ODORANT IS ADDED TO THE GAS USED BY THIS WATER HEATER.
TABLE OF CONTENTS Water Heater Safety .......................................................................................................................................................................... 1 -2 Safe Installation, Use and Service ...................................................................................................................................................... 3 Safety Precautions ...........................................................................................
SAFE INSTALLATION, USE AND SERVICE Your 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 and instructions throughout this manual.
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 ignition sources away from faucets after extended period of non-use. Read instruction manual before installing, using or servicing water heater.
TYPICAL INSTALLATION GET TO KNOW YOUR WATER HEATER - GAS MODELS A B C D E F G H I Vent Pipe Draft Hood Anode (Not Shown) Hot Water Outlet Insulation Gas Supply Piping Manual Gas Shut-off Valve Ground Joint Union Drip Leg (Sediment Trap) J K L M N O P Q R Inner Door Outer Door Union Inlet Water Shut-off Valve Cold Water Inlet Inlet Dip Tube Temperature-Pressure Relief Valve Rating Plate Flue Baffle S T U V W X Y Z AA BB * INSTALL IN ACCORDANCE WITH LOCAL CODES. * DRIP LEG AS REQUIRED BY LOCAL CODES.
INSTALLING YOUR GAS WATER HEATER Important Information About This Water Heater Unpacking the Water 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 environments.
If flammable liquids or vapors have spilled or leaked in the area of the water heater, leave the area immediately and call the fire department from a neighbor’s home. Do not attempt to clean the spill until all ignition sources have been extinguished. WARNING FV Sensor Fire or Explosion Hazard • Read instruction manual before installing, using or servicing water heater. FIGURE 1. • Improper use may result in fire or explosion.
• • IMPORTANT: 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, including those from improper installation, may cause early failure of the tank due to corrosion if not repaired.
GAS SUPPLY WARNING MANUAL GAS SHUT-OFF VALVE GROUND JOINT UNION DISCHARGE PIPE (DO NOT CAP OR PLUG) CHECK WITH LOCAL UTILITY FOR MINIMUM HEIGHT Explosion Hazard 3” MINIMUM • Use a new CSA approved gas supply line. • Install a shut-off valve. 6” MAXIMUM AIR GAP DRIP LEG SUITABLE DRAIN • Do not connect a natural gas water heater to an L.P. gas supply. FIGURE 5. • Do not connect an L.P. gas water heater to a natural gas supply.
LP Gas Only Liquefied petroleum gas is over 50% heavier than air and in the occurrence of a leak in the system, the gas will settle at floor level. Basements, crawl spaces, closets and areas below ground level will serve as pockets for the accumulation of gas. Before lighting an L.P. gas water heater, smell all around the appliance at floor level. If you smell gas, follow the instructions as given in the warning on the front page. WARNING When your L.P.
COMBUSTION AIR & VENTILATION TABLE 3 WARNING BTUH Input Minimum Square Feet with 8’ Ceiling Vent must be installed by a qualified technician using the installation instructions. 30,000 188 9 x 21 45,000 281 14 x 20 Examples of a qualified technican include: gas technicians, authorized gas company personel, and authorized service persons.
fresh air can be taken from the outdoors or from crawl or attic spaces that freely communicate with the outdoors. Attic or crawl spaces cannot be closed and must be properly ventilated to the outside. 12” MAXIMUM Ductwork must be of the same cross-sectional area as the free area of the opening to which they connect. The minimum dimension of rectangular air ducts cannot be less than three inches.
GABLE VENT TO OUTDOORS ALTERNATIVE OPENING LOCATION INSTALL ABOVE INSULATION CONFINED SPACE 1 SQ. INCH CONFINED OUTLET AIR TO ATTIC 1 SQ. INCH PER 4000 BTUH PER 3000 BTUH SPACE INLET AIR FROM THE CRAWL SPACE ALTERNATE AIR INLET ALL AIR FROM OUTDOORS - USING A SINGLE PERMANENT OPENING 1 SQ. INCH PER 4000 BTUH FIGURE 11.
Align the legs of the draft hood with the slots provided. Insert the draft hood leg tips into slots on the flue damper’s flange as shown in Figure 12. Secure the draft hood by twisting or bending the leg tips. See Figure 12. Do not alter the draft hood in any way. If you are replacing an existing water heater, be sure to use the new draft hood supplied with the water heater. codes, the “National Fuel Gas Code”, ANSI Z223.1(NFPA 54)-current edition.
NFPA 54, ANSI Z223.1-current edition and the guidelines set forth by prevailing local codes. WATER SYSTEM PIPING Piping Installation LISTED VENT CAP 3 FT. MINIMUM Piping, fittings, and valves should be installed according to the installation drawing (Figure 16). If the indoor installation area is subject to freezing temperatures, the water piping must be protected by insulation. 2 FT. MINIMUM ABOVE ANY OBJECT WITHIN 10 FT.
Please note the following: • The system should be installed only with piping that is suitable for potable (drinkable) water such as copper, CPVC, or polybutylene. This water heater must not be installed using iron piping or PVC water piping. • Use only pumps, valves, or fittings that are compatible with potable water. • It is recommend that only full flow ball or gate valves are used in water piping installations. The use of valves that may cause excessive restriction to water flow is not recommended.
Temperature and Pressure Relief Valve The Discharge Line: • Must not be smaller than the pipe size of the relief valve or have any reducing coupling installed in the discharge line. Explosion Harzard • • Temperature-pressure relief valve must comply with ANSI Z21.22-CSA 4.4 and ASME code. Must not be capped, blocked, plugged or contain any valve between the relief valve and the end of the discharge line. • • Properly sized temperaturepressure relief valve must be installed in opening provided.
IMPORTANT INFORMATION ABOUT THIS WATER HEATER This gas water heater was manufactured to voluntary safety standards to reduce the likelihood of a flammable vapor ignition incident. The new technology used in meeting these standards makes this product more sensitive to installation errors. Please review the following checklist and make any required installation upgrades or changes.
OPERATING YOUR WATER HEATER Lighting Instructions WARNING Read and understand these directions thoroughly before attempting to start or re-start the water heater. Make sure the viewport is not missing or damaged. (See Figure 27) Make sure the tank is completely filled with water before turning the power switch on. Check the data plate near the gas control valve/thermostat for the correct gas. Do not use this water heater with any gas other than the one listed on the data plate.
Checking the Draft Water Temperature Regulation Water temperature over 125°F (52°C) can cause servere burns instantly resulting in severe injury or death. WARNING Burn Hazard Children, the elderly, and the physically or mentally disabled are at highest risk for scald injury. Do not touch vent. Doing so can result in burns. Feel water before bathing or showering. Temperature limiting valves are available.
160°F (Approx.) OFF C A B RY VE OT H Status Light 120°F Position HOT RY E V OT H Water Temperature °F Time for 1st Degree Burn (Less Severe Burns) 110 (normal shower temp.) 116 (pain threshold) HOT • 116 35 minutes 1 minute 5 minutes 131 5 seconds 25 seconds VAC 140 2 seconds 5 seconds 70°F (Approx.) 149 1 second 2 seconds 154 instantaneous 1 second LOW 110°F (Approx.
ELECTRICAL CONNECTIONS/WIRING DIAGRAM Electrical Connections WARNING Before plugging in the water heater, always make sure: • The Voltage and frequency correspond to that specified on the water heater. • The electrical outlet has the proper overload fuse or breaker protection. • Water heater to be located within 6 feet of 120VAC outlet. • Unit is to connect to a 120VAC electrical supply outlet (extension cord is not allowed). • The water heater and the outlet are properly grounded.
Operational Conditions periods of heat-up and cool-down. 2. Condensation causes sizzling and popping within the burner area and should be considered normal. 3. Sediment buildup in the tank bottom will create varying amounts of noise and may cause premature tank failure. Drain and flush the tank as directed under the “Draining and Flushing” section. Smoke/Odor Condensation Whenever the water heater is filled with cold water, some condensate will form while the burner is on.
Draining and Flushing Anode Rod/Water 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 rod and the water.
Temperature and Pressure Relief Valve properly. To 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 position. See Figure 25.
Removing the Burner from the Manifold/ Burner Assembly OLD PILOT/IGNITER FLAME SENSOR ASSEMBLY Natural Gas (Low Nox) & L.P. Gas Burner SCREWS 1. Take off the burner by removing the two (2) screws located underneath the burner. 2. Check the burner to see if it is dirty or clogged. The burner may be cleaned with soap and hot water (Figure 28). OTHER FITTINGS NOT SHOWN FOR CLARITY PILOT TUBE FIRST BEND(S) SCREWS FIGURE 30. 7. BURNER (BOTTOM VIEW) FIGURE 28.
Cleaning the Combustion Chamber and Flame-arrestor 2. Inspect the view port for damage and replace as required. 1. 3. Insert the manifold/burner assembly into the burner compartment, making sure that the tip of the manifold tube engages in the slot of the bracket inside the combustion chamber (Figures 33 & 34). Follow procedure outlined in “Removing the Manifold/ Burner Assembly”. 2. Use a vacuum cleaner/shop vac to remove all loose debris in the combustion chamber (Figure 32).
3. Drain the water heater. Refer to the section of “Draining and Flushing” section and follow the procedure. CLOSE-UP INSIDE VIEW OF THE COMBUSTION CHAMBER. 5. Disconnect the wire harness, flammable vapor sensor wires, and igniter wire from the gas control valve/ thermostat. Disconnect pilot tube (7/16” wrench) and manifold tube (3/4” wrench) at the gas control valve/ thermostat (Figure 26). NOTE: L.P.
FVIR System Operational Checklist 1. Manifold gasket properly sealed. 5. No leaks at pilot and manifold connection. 2. Viewport not damaged or cracked. 6. Manifold door screws securely tightened. 3. Flame-arrestor free of debris and undamaged. 7. Depress the button on the thermal switch 4. Two piece wire connector properly installed.
INSUFFICIENT HOT WATER 1. 2. 3. 4. 5. 6. 7. 8. 9. Thermostat set too low Sediment or lime in tank Water heater too small Wrong piping connections Leaking faucets Wasted hot water Long runs of exposed piping Hot water piping in outside wall Low gas pressure 1. 2. 3. 4. 5 6. 7. 8. 9.
STATUS LIGHT TROUBLESHOOTING FLOWCHART Status Light Code LED FLASH SEQUENCE CONTROL STATUS Short flash once every four second IDLE (No call for heat, no fault conditions) “Heartbeat”, alternates bright/dim Call for Heat (No fault conditions) One Flash, three second pause Low Flame Signal (control continues to operate) Two Flash, three second pause End Switch Failed Closed CORRECTIVE ACTION Turn the power switch on the gas control valve to the “OFF” position and unplug the power cord from the pow
STATUS LIGHT TROUBLESHOOTING FLOWCHART LED FLASH SEQUENCE Six-Two Flash, three second pause CONTROL STATUS Soft Lockout* - Recycle Limit - Flame Lost END Switch Fails Six-Three Flash, three second pause Soft Lockout* - Recycle Limit - Flame Lost CORRECTIVE ACTION Turn the power switch on the gas control valve to the “OFF” position and unplug the power cord from the power outlet. 1.
SEQUENCE OF OPERATION CHART Apply Power to Appliance. Is there a Call for Heat. Y Is Damper Closed? N Will not attempt to light. 2 flash error code. See Corrective Action Table on pages 31-32. N Gas Valve attempts to open damper for 30 seconds, displays 3 flash error code, and then waits 2 mintues before attempting to open damper again. See Corrective Action Table pages 31-32. N Will not light. 8-4 flash error code. See Corrective Action Table on pages 31-32. Damper Energizes.
REPAIR PARTS ILLUSTRATION When ordering repair parts always give the following information: 1. 2. 3. 4. 1 Model, serial, and product number Type of gas Item number Parts description 5 4 Repair Parts List 2 Item No.
Listed Parts Kits and Illustrations Item 12A: Pilot/Igniter-Flame Sensor assembly kit, which contains the pilot, igniter-flame sensor, and retainer clip (Natural Gas) Item 12B: Pilot/Igniter-Flame Sensor assembly kit, which contains the pilot, igniter-flame sensor, and retainer clip (L.P. Gas) Item 13A: Burner (Natural Gas/L.P. Gas) Item 13B: Burner (L.P.
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LIMITED RESIDENTIAL GAS WARRANTY THIS WARRANTY IS APPLICABLE TO THE ORIGINAL OWNER ONLY, in accordance with the warranty terms and conditions specified below.
CLAIM PROCEDURE Any claim under this warranty should be initiated with the dealer who sold the heater, or with any other dealer handling the warrantor’s products. If this is not practical, the owner should contact: State Industries, Inc., 500 Tennessee Waltz Parkway, Ashland City, Tennessee 37015. Phone: 1.800.365.0024 or visit our website: www.statewaterheaters.com. TO ANY PERSONS OR PROPERTY, WHETHER DIRECT OR INDIRECT, AND WHETHER ARISING IN CONTRACT OR IN TORT.
