Download 318557-000 - State Water Heaters

Service Handbook
COMMERCIAL / RESIDENTIAL GAS WATER HEATERS
500 Tennessee Waltz Parkway
Ashland City, TN 37015
FOR MODELS:
SHE 50-100 NE, SHE 50-100 PE
GP650 YTPDT, GP650 HTPDT
SERIES 120 & 121
INSTALLATION CONSIDERATIONS - PRE SERVICE
CHECKS - WATER HEATER CONSTRUCTION OPERATION & SERVICE - TROUBLESHOOTING
SERVICING SHOULD ONLY BE PERFORMED BY A QUALIFIED SERVICE AGENT
PRINTED IN THE U.S.A. 0410
318557-000
TABLE OF CONTENTS
TABLE OF CONTENTS.......................................................................... 1
&RQWURO6\VWHP+DUGZDUH ......................................................... 37
INTRODUCTION .................................................................................... 2
8,08VHU,QWHUIDFH0RGXOH ............................................... 37
4XDOL¿FDWLRQV ..................................................................................... 2
&&%&HQWUDO&RQWURO%RDUG .............................................. 39
6HUYLFH:DUQLQJ ................................................................................ 2
&&%&RYHU5HPRYDO$QG5HSODFHPHQW ............................. 40
6HUYLFH5HPLQGHU .............................................................................. 2
&&%&LUFXLW%RDUG/D\RXW ................................................... 41
7RROV5HTXLUHG ................................................................................... 2
&&%&RQQHFWLRQ,GHQWL¿FDWLRQ ........................................... 42
INSTALLATION CONSIDERATIONS ..................................................... 3
:LULQJ'LDJUDP .......................................................................... 44
,QVWUXFWLRQ0DQXDO ............................................................................. 3
&21752/6<67(023(5$7,21 ................................................ 45
&ORVHG:DWHU6\VWHPV ...................................................................... 3
Overview .................................................................................... 45
7KHUPDO([SDQVLRQ ............................................................................ 3
&RQWURO6\VWHP)HDWXUHV .................................................... 45
$LU5HTXLUHPHQWV ............................................................................... 3
&RPPHUFLDO$QG5HVLGHQWLDO0RGHOV .................................. 46
&RQWDPLQDWHG$LU ............................................................................... 3
&RQWURO6\VWHP1DYLJDWLRQ.................................................. 46
9HQWLQJ ............................................................................................... 4
8VHU,QSXW%XWWRQV .............................................................. 46
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'HVNWRS6FUHHQ................................................................... 46
0D[LPXP(TXLYDOHQW/HQJWK5HTXLUHPHQWV ............................... 4
6WDWXV,FRQV ........................................................................ 47
,QWDNH$LU&RQQHFWLRQ .................................................................. 5
2SHUDWLQJ6WDWHV ................................................................. 48
(OHFWULFDO5HTXLUHPHQWV ..................................................................... 6
&RQWURO6\VWHP0HQXV .............................................................. 48
*URXQGLQJDQG3RODULW\ ............................................................... 6
7HPSHUDWXUHV ...................................................................... 49
3RZHU6XSSO\7HVW ...................................................................... 6
Heater Status ...................................................................... 50
,QVWDOODWLRQ&KHFN/LVW ........................................................................ 7
'LVSOD\6HWWLQJV .................................................................. 51
)($785(6$1'&20321(176 ......................................................... 8
+HDWHU,QIRUPDWLRQ .............................................................. 51
)URQW%DFN9LHZV ........................................................................... 8
Current Fault ....................................................................... 52
7RS9LHZ ............................................................................................ 9
)DXOW+LVWRU\ ........................................................................ 52
&RPEXVWLRQ%ORZHU%XUQHU$VVHPEO\ ............................................ 9
)DXOW2FFXUUHQFH................................................................. 52
OPERATION AND SERVICE ............................................................... 10
5HVWRUH)DFWRU\'HIDXOWV .................................................... 52
+RZ,W:RUNV ................................................................................... 10
6HUYLFH&RQWDFW,QIRUPDWLRQ ................................................ 53
&RPEXVWLRQ%ORZHU ..........................................................................11
6HTXHQFH2I2SHUDWLRQ ............................................................. 54
%XUQHU$VVHPEO\ ............................................................................. 12
6HTXHQFH2I2SHUDWLRQ)ORZ&KDUW .......................................... 55
&RPEXVWLRQ%ORZHUDQG%XUQHU5HPRYDO ....................................... 14
TROUBLESHOOTING ................................................................... 56
)ODPH6HQVRU .................................................................................. 18
5RXJK6WDUWLQJ5RXJK2SHUDWLRQ ........................................ 56
)ODPH6HQVLQJ2SHUDWLRQ ......................................................... 18
1RW(QRXJK+RW:DWHU ........................................................ 56
)ODPH6HQVLQJ&XUUHQW7HVW ...................................................... 19
+HDWHU6WDWXV0HQX ............................................................ 56
,JQLWHU ............................................................................................... 20
7KLQJV7R&KHFN%HIRUH6HUYLFLQJ ...................................... 56
,JQLWHU&XUUHQW7HVW .................................................................... 20
5HVHWWLQJ7KH&RQWURO6\VWHP ............................................ 56
Venturi ............................................................................................. 22
&RQWURO6\VWHP8QUHVSRQVLYH ................................................... 57
Gas Valve ........................................................................................ 23
8,0/&',V%ODQN ............................................................. 57
*DV9DOYH9ROWDJH7HVWV............................................................ 23
8,0,V,QRSHUDEOH ................................................................ 57
*DV9DOYH5HPRYDO ................................................................... 24
)DXOW0HVVDJHV ......................................................................... 58
Gas Pressure ................................................................................... 25
AC Reversed ....................................................................... 58
Gas Pressure Test ..................................................................... 26
7HPS3UREH2SHQ ............................................................... 58
*DV)ORZ7HVW ........................................................................... 27
7HPS3UREH6KRUW ............................................................... 58
3UHVVXUH6ZLWFKHV ........................................................................... 28
)ODPH6HQVRU6KRUW ............................................................ 59
&RQVWUXFWLRQ2SHUDWLRQ .......................................................... 28
)ODPH'HWHFW(UURU .............................................................. 59
&RQWURO6\VWHP0RQLWRULQJ ........................................................ 29
(QHUJ\&XW2XW(&2 ........................................................ 60
3UHVVXUH6ZLWFK7HVWV ..................................................................... 31
%ORFNHG$LU,QWDNH ............................................................... 61
&RQWLQXLW\7HVW'XULQJ6WDQGE\ ................................................. 31
%ORFNHG([KDXVW ................................................................. 62
&RQWLQXLW\7HVW'XULQJ2SHUDWLRQ .............................................. 32
%ORZHU3URYHU)DLOXUH.......................................................... 62
3UHVVXUH7HVW'XULQJ2SHUDWLRQ ................................................ 32
%ORZHU3URYHU2SHQ ............................................................ 63
7HPSHUDWXUH3UREH .......................................................................... 35
/RZ,JQLWHU&XUUHQW.............................................................. 64
7HPSHUDWXUH6HQVRU7HVW .......................................................... 35
,JQLWLRQ)DLOXUH..................................................................... 65
(&2&RQWLQXLW\7HVW .................................................................. 36
&RPPXQLFDWLRQ)DLOXUH ....................................................... 66
1
INTRODUCTION
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QUALIFICATIONS
QUALIFIED INSTALLER OR SERVICE AGENCY
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INSTALLATION CONSIDERATIONS
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PRESSURE SWITCHES
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CONSTRUCTION
Normal State
Activated State
(open switch contacts)
Switch Contacts
(closed switch contacts)
Wiring Terminals
Internal Linkage
Vent Port
Flexible Diaphragm
Sensing Port
TYPES AND APPLICATION
Normal State
Activated State
Blower Prover
Pressure Switch
Normally open contacts ,
close on a rise in pressure .
Blocked Intake Air
Pressure Switch
Normally closed contacts,
open on a fall in pressure .
Blocked Exhaust
Pressure Switch
Normally closed contacts,
open on a rise in pressure .
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PRESSURE SWITCH FAULT MESSAGES
Blower Prover Failure
Blower Prover Open
Fault occurred 2 mins ago
Fault occurred 2 mins ago
The blower prover switch is
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The blower prover switch remains
open after the blower has been
energized.
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
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Blocked Air Intake
Blocked Exhaust
Fault occurred 2 mins ago
Fault occurred 2 mins ago
The combustion air intake is
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The exhaust is blocked or
restricted. Ensure
condensate hose is draining.
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
CHANGE
BACK
ADVANCED
CHANGE
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TEMPERATURE SENSOR
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DUHWKHUPDOO\VHQVLWLYHUHVLVWRUV$VWKHZDWHUWHPSHUDWXUHULVHVWKHUHVLVWDQFHPHDVXUHGLQRKPVRIWKH
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DQGXVHVWKLVGDWDWRDFWLYDWHDQGGHDFWLYDWHKHDWLQJF\FOHVDQGGLVSOD\VWKLVWHPSHUDWXUHLQWKH&RQWURO
6\VWHPPHQXVVHH'HVNWRS6FUHHQRQSDJHDQG7HPSHUDWXUHV0HQXRQSDJH
7KH &RQWURO 6\VWHP FRQVWDQWO\ PRQLWRUV WKH7HPSHUDWXUH 6HQVRU7KH &RQWURO 6\VWHP LV SURJUDPPHG WR
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RKPVRSHQ
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‡ 7KHUHVLVWDQFHLVDERYHRKPVRSHQRUEHORZRKPVVKRUWHG
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6HUYLFLQJVKRXOGRQO\EHSHUIRUPHGE\D4XDOL¿HG6HUYLFH$JHQW
35
7$%/(
WATER TEMPERATURE
CELSIUS
FAHRENHEIT
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RESISTANCE IN OHMS
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26,435
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11,974
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5,862
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3,066
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2,503
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1,698
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1,177
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VZLWFKKDVUHVHWSURSHUO\,IWKH&RQWURO6\VWHPFRQWLQXHVWRORFNRXWGLVSOD\LQJEnergy Cut Out
(ECO)RQWKH/&'ZLWKFRQWLQXLW\WKURXJKWKH(&2SUHVHQWFDOOWKHWROOIUHHVXSSRUWSKRQHQXPEHU
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UIM CIRCUIT BOARD BACK
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CCB ENCLOSURE WITH FRONT REMOVED
CCB CIRCUIT BOARD
120 VAC X 24 VAC
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CCB ENCLOSURE
CCB ENCLOSURE
COVER SCREWS (2)
TRANSFORMER COVER
CCB CIRCUIT BOARD
MOLDED CLIPS
RAISED EDGES (3)
FOR WIRING
STRAIN RELIEF
FRONT
TOP OF WATER HEATER
FRONT COVER ON
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CCB CIRCUIT BOARD LAYOUT
CCB (CENTRAL CONTROL BOARD)
1
1
1
2
2
2
1
3
3
4
2
4
4
5
J2
J3
J4
J5
J1
J6
Type
Tstat
Spare
Retries
OPEN
Yes
2 3 4
Use
1
1 Retry
Ext
Input
3
No
15
12
9
6
3
14
11
8
5
2
13
10
7
4
1
Vent
Spare
S1 DIPSWITCH
J7
4
3
2
1
J9
J13
J10
1
5
J11
1
3
2
6
J15
2
4
3
7
1
4
8
2
J16
Use
Yes
Type
Tstat
Spare
OPEN
Ext
Input
3
Retries
1
1 Retry
2 3 4
S1 DIPSWITCH DETAIL
No
Vent
Spare
Dipswitch Operation:
Along one side of the dipswitch array there are numbers, 1-4. On the other side of the dipswitch
is the word “OPEN.” The dipswitches are rocker type switches, if one side of the rocker is down the
other side will be up. Pressing a rocker down on the side of the array labeled “OPEN,” opens the switch.
Pressing a rocker down on the side of the array labeled with the numbers 1-4 closes the dipswitch.
CHANGING NUMBER OF IGNITION TRIALS BEFORE LOCK OUT
NOTE: Always turn off power to the water heater before changing dipswitch settings.
Set dipswitch #4 to the open position for 1 trial for ignition before Ignition Failure lock out. Set dipswitch
#4 to the closed position for 3 trials for ignition before Ignition Failure lock out.
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CCB CONNECTION IDENTIFICATION
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PIN #
1
2
3
4
5
DESCRIPTION
9$&KRWWRWUDQVIRUPHU
1RWXVHG
9$&QHXWUDOWRWUDQVIRUPHU
9$&RXWIURPWUDQVIRUPHU
9$&RXWIURPWUDQVIRUPHU
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PIN #
1
2
3
4
DESCRIPTION
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9$&QHXWUDOWR&RPEXVWLRQ%ORZHUSLQVRFNHWVHH)LJXUHRQSDJH
1RWXVHG
1RWXVHG
-6RFNHW9$&3RZHU6XSSO\
PIN #
1
2
3
DESCRIPTION
9$&KRW
(DUWK*URXQG
120 VAC neutral
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-6RFNHW,JQLWHU9$&+6,KRWVXUIDFHLJQLWHU
PIN #
1
2
DESCRIPTION
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120 VAC neutral
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TEMPERATURES MENU
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ADVANCED
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Fault History
1:
Blocked Air Intake (A7)
51 mins ago
Blocked Exhaust (A8)
54 mins ago
Low Gas Pressure (A6)
57 mins ago
Blower Prover Failure (AC)
2:
3:
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DESCRIPTION/ACTION
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Fault Occurrence
Ignition Failure
ECO
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Blocked Exhaust
Thermostat Input 4
Blower Prover
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4. ,IDQ\RIWKHVHOHFWHGGLDJQRVWLFFKHFNVIDLOWKH&RQWURO6\VWHPZLOOORFNRXWDQGGLVSOD\DVSHFL¿FIDXOW
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the Blower Prover OpenIDXOWPHVVDJHRQWKH/&'
7. ,IWKH%ORZHU3URYHUVZLWFKFRQWDFWVDUHFRQ¿UPHGFORVHGWKH&RQWURO6\VWHPHQHUJL]HVWKH,JQLWHUIRUWKH
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9. ,I,JQLWHUFXUUHQWLVFRQ¿UPHGDWRUDERYHWKHUHTXLUHGPLQLPXPWKH&RQWURO6\VWHPHQHUJL]HVWKH9ROW
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11. 7KH &RQWURO 6\VWHP PRQLWRUV ÀDPH VHQVLQJ FXUUHQW WR FRQ¿UP D ÀDPH LV SUHVHQW DW WKH %XUQHU 6HH
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WLPHV$IWHUWKUHHIDLOHGWULDOVIRULJQLWLRQWKH&RQWURO6\VWHPZLOOORFNRXWDQGGLVSOD\WKHIgnition Failure
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14. 7KH&RQWURO6\VWHPZLOOFRQWLQXHKHDWLQJWKHZDWHUXQWLOWKH2SHUDWLQJ6HW3RLQWLVUHDFKHG$WWKLVSRLQW
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16. 7KH&RQWURO6\VWHPQRZHQWHUVWKH6WDQGE\RSHUDWLQJVWDWHZKLOHFRQWLQXLQJWRPRQLWRUZDWHUWHPSHUDWXUH
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54
6HUYLFLQJVKRXOGRQO\EHSHUIRUPHGE\D4XDOL¿HG6HUYLFH$JHQW
SEQUENCE OF OPERATION FLOW CHART
If tank temperature drops below Operating Set Point minus
Differential setting a heating cycle is activated
Control System performs diagnostic system check
Normal State of all pressure switches and ECO are checked
Blower Prover pressure is switch verified open
All other pressure switches and ECO are verified closed
NO
Control System Locks Out
Displays Fault Msg
YES
Combustion Blower is energized
Pre-Purge cycle
Blower Prover switch contacts confirmed
closed by Control System
NO
Control System Locks Out
“Blower Prover Open”
Fault Msg is displayed
YES
Igniter is energized for warm up period
Does Control System sense minimum
0.5 AC amps through the Igniter?
NO
Control System Locks Out
“Low Igniter Current”
Fault Msg is displayed
YES
24 Volt Gas Valve is energized
gas flows to Burner
Does Control System sense minimum flame sensing
of 1.0 μA (DC micro amps) through Flame Sensor?
YES
NO
Water is heated to
set point
24 Volt Gas Valve
de-energized
24 Volt Gas Valve
de-energized
30 second
Inter-Purge cycle
30 second
Post-Purge cycle
Retries up to
two more times
Control System goes
into Standby mode
Control System Locks Out
“Ignition Failure”
Fault Msg is displayed
6HUYLFLQJVKRXOGRQO\EHSHUIRUPHGE\D4XDOL¿HG6HUYLFH$JHQW
55
TROUBLESHOOTING
7KH &RQWURO 6\VWHP SHUIRUPV H[KDXVWLYH VHOI GLDJQRVWLFV DQG GLVSOD\V GHWHFWHG IDXOW FRQGLWLRQV LQ SODLQ
(QJOLVK IDXOW PHVVDJHV RQ WKH /&' ZKHQ WKHUH LV D SUREOHP :KHQ WKH &RQWURO 6\VWHP GHFODUHV D IDXOW
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WKDWIROORZWKH¿UVWFROXPQZLOOVKRZDOLVWRIWKLQJVWRFKHFNDQGUHSDLUIRUDJLYHQSUREOHPRUIDXOWFRQGLWLRQ
7KHVHFRQGFROXPQZLOOVKRZWKHIDXOWPHVVDJHDVGLVSOD\HGRQWKH/&'DORQJZLWKDQH[SODQDWLRQ
ROUGH STARTING/ROUGH OPERATION
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‡ ,QVSHFWWKH%XUQHUIRUGHEULVRUGDPDJHVHH&RPEXVWLRQ%ORZHUDQG%XUQHU5HPRYDORQSDJH
NOT ENOUGH HOT WATER
‡ 7KHKHDWLQJFDSDFLW\RIWKHZDWHUKHDWHUKDVEHHQH[FHHGHG
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‡ 'LSWXEHLQVLGHZDWHULQOHWFRQQHFWLRQPLVVLQJ
HEATER STATUS MENU
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%ORFNHG([KDXVWVZLWFKHV7KLVLQIRUPDWLRQLVGLVSOD\HGLQUHDOWLPH8VHWKLVPHQXZKHQWURXEOHVKRRWLQJWR
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THINGS TO CHECK BEFORE SERVICING
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RESETTING THE CONTROL SYSTEM
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IMPORTANT SERVICE REMINDER
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EHWZHHQFRPSRQHQWV3HUIRUPDFORVHYLVXDOLQVSHFWLRQRIDOOZLULQJDQGFRQQHFWRUVWRDQGIURPDJLYHQ
FRPSRQHQWEHIRUHUHSODFHPHQW(QVXUHZLUHVZHUHVWULSSHGEHIRUHEHLQJFULPSHGLQDZLUHFRQQHFWRUHQVXUH
ZLUHVDUHFULPSHGWLJKWO\LQWKHLUFRQQHFWRUVHQVXUHFRQQHFWLRQSLQVLQVRFNHWVDQGSOXJVDUHQRWGDPDJHG
RUZRUQHQVXUHSOXJVDQGVRFNHWVDUHPDWLQJSURSHUO\DQGSURYLGLQJJRRGFRQWDFW)DLOXUHWRSHUIRUPWKLV
FULWLFDOVWHSRUIDLOLQJWRSHUIRUPWKLVVWHSWKRURXJKO\RIWHQUHVXOWVLQQHHGOHVVGRZQWLPHXQQHFHVVDU\SDUWV
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56
6HUYLFLQJVKRXOGRQO\EHSHUIRUPHGE\D4XDOL¿HG6HUYLFH$JHQW
CONTROL SYSTEM UNRESPONSIVE
DISPLAYED MESSAGE/CONDITION/INDICATES
8,0/&',V%ODQN
7KH/&'RQWKH8,0LVQRWVKRZLQJDQ\GDWD7KHZDWHU
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water heater.
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‡ &DOOWKHWROOIUHHVXSSRUWSKRQHQXPEHURQWKHEDFN
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57
FAULT MESSAGES
DISPLAYED MESSAGE/CONDITION/INDICATES
$&5HYHUVHG
7KH &RQWURO 6\VWHP KDV GHWHFWHG WKH SRZHU VXSSO\
SRODULW\LVUHYHUVHG
AC Reversed
Fault occurred 2 mins ago
Power supply to water heater
has reversed polarity.
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
CHANGE
BACK
ADVANCED
,PSRUWDQW6HUYLFH5HPLQGHU
:KHQ SHUIRUPLQJ DQ\ WURXEOHVKRRWLQJ VWHSV RXWOLQHG LQ
WKLV PDQXDO DOZD\V FRQVLGHU WKH ZLULQJ DQG FRQQHFWRUV
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IURP WKH 7HPSHUDWXUH 6HQVRU LQVLGH WKH 7HPSHUDWXUH
3UREH
Temp Probe Open
Fault occurred 2 mins ago
There is a problem with the
temperature probe.
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
CHANGE
BACK
ADVANCED
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7KH &RQWURO 6\VWHP KDV GHWHFWHG OHVV WKDQ RKPV
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Temp Probe Short
Fault occurred 2 mins ago
There is a problem with the
temperature probe.
Call a service professional:
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(press [DOWN] for more....)
CHANGE
58
BACK
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FAULT MESSAGES
DISPLAYED MESSAGE/CONDITION/INDICATES
)ODPH6HQVRU6KRUW
7KH &RQWURO 6\VWHP KDV GHWHFWHG WKH )ODPH 6HQVRU LV
JURXQGHG
Flame Sensor Short
Fault occurred 2 mins ago
The flame sensor is grounded.
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
CHANGE
BACK
ADVANCED
POSSIBLE CAUSES - CHECK/REPAIR
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NOTES
NOTES
500 Tennessee Waltz Parkway, Ashland City, TN 37015
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