State GPX 40 YXRS User Manual
Instruction Manual
RESIDENTIAL GAS WATER HEATERS
NOT FOR USE IN MANUFACTURED (MOBILE) HOMES
GAMA certification applies to
all residential gas water
heaters with capacities of 20
to 100 gallons with input rating
of 75,000 BTU/Hr. or less.
®
C3 Technology® Gas Water Heaters meet the new
ANSI Z21.10.1 standard that deals with 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.
ALL TECHNICAL AND WARRANTY QUESTIONS: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS
PURCHASED. IF YOU ARE UNSUCCESSFUL, PLEASE WRITE TO THE COMPANY LISTED ON THE RATING PLATE ON THE WATER HEATER.
KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE
WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.
PRINTED IN THE U.S.A 0905 PART NO. 184165-003
1
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 own water heater to warn you and
others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual. It is very
important that the meaning of each safety message is understood by you and others who install, use or service this water heater.
All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message and
how to avoid the risk of injury.
IMPORTANT DEFINITIONS
• Qualified Installer: A qualified installer must have ability equivalent to a licensed tradesman in the fields of plumbing,
air supply, venting and gas supply, including a thorough understanding of the requirements of the National Fuel Gas
Code as it relates to the installation of gas fired water heaters. The qualified installer must also be familiar with the
design features and use of flammable vapor ignition resistant water heaters, and have a thorough understanding of this
instruction manual.
• Service Agency: A service agency also must have ability equivalent to a licensed tradesman in the fields of plumbing,
air supply, venting and gas supply, including a thorough understanding of the requirements of the National Fuel Gas
Code as it relates to the installation of gas fired water heaters. The service agency must also have a thorough
understanding of this instruction manual, and be able to perform repairs strictly in accordance with the service guidelines
provided by the manufacturer.
• Gas Supplier: The Natural Gas or Propane Utility or service who supplies gas for utilization by the gas burning
appliances within this application. The gas supplier typically has responsibility for the inspection and code approval of
gas piping up to and including the Natural Gas meter or Propane storage tank of a building. Many gas suppliers also
offer service and inspection of appliances within the building.
2
GENERAL SAFETY
3
TABLE OF CONTENTS
SAFE INSTALLATION, USE AND SERVICE ............................... 2
GENERAL SAFETY .................................................................. 3
TABLE OF CONTENTS .............................................................. 4
INTRODUCTION ........................................................................ 4
Preparing for the New Installation ................................... 4
TYPICAL INSTALLATION ...................................................... 5-6
LOCATING THE NEW WATER HEATER ..................................... 7
Facts to Consider About Location ............................... 7-8
Insulation Blankets ........................................................... 8
Combustion Air and Ventilation for Appliances
Located in Unconfined Spaces........................................ 8
Combustion Air and Ventilation for Appliances
Located in Confined Spaces ........................................ 8-9
INSTALLING THE WATER HEATER ......................................... 10
Water Piping .............................................................. 10-11
Temperature-Pressure Relief Valve ............................... 11
Filling the Water Heater .................................................. 12
Venting ..................................................................... 12-13
Gas Piping ................................................................ 13-14
Sediment Traps .............................................................. 14
LIGHTING & OPERATING LABEL ............................................ 15
TEMPERATURE REGULATION ................................................ 16
FOR YOUR INFORMATION ............................................... 16-17
Start Up Conditions ........................................................ 16
Draft Hood Operation ..................................................... 16
Condensate .............................................................. 16-17
Smoke/Odor .................................................................... 17
Thermal Expansion ......................................................... 17
Strange Sounds..............................................................17
OPERATIONAL CONDITIONS .................................................. 18
Smelly Water .................................................................. 17
“Air” in Hot Water Faucets ............................................. 17
High Temperature Shut Off System ...............................17
PERIODIC MAINTENANCE .. ..................................................... 18
Venting System Inspection ............................................ 18
Burner Inspection ........................................................... 18
Burner Cleaning .............................................................. 18
Housekeeping .......................................................... 18-19
Anode Rod Inspection .................................................... 19
Temperature-Pressure Relief Valve Operation.............. 19
Draining .......................................................................... 19
Drain Valve Washer Replacement ........................... 19-20
Service ........................................................................... 20
LEAKAGE CHECKPOINTS ...................................................... 20
REPAIR PARTS ....................................................................... 21
TROUBLESHOOTING .............................................................. 22
NOTES .................................................................................... 23
WARRANTY ..................................................................... Insert
INTRODUCTION
Thank You for purchasing this water heater. Properly installed and
maintained, it should give you years of trouble free service.
Abbreviations Found In This Instruction Manual:
• CSA - Canadian Standards Association
• ANSI - American National Standards Institute
• NFPA - National Fire Protection Association
• ASME - American Society of Mechanical Engineers
• GAMA - Gas Appliance Manufacturer’s Association
This gas-fired water heater is design certified by CSA INTERNATIONAL
under American National Standard/CSA Standard for Gas Water Heaters
ANSI Z21.10.1 • CSA 4.1 (current edition).
PREPARING FOR THE INSTALLATION
1. Read the “General Safety” section, page 3 of this manual first and
then the entire manual carefully. If you don’t follow the safety rules,
the water heater will not operate properly. It could cause DEATH,
SERIOUS BODILY INJURY AND/OR PROPERTY DAMAGE.
This manual contains instructions for the installation, operation, and
maintenance of the gas-fired water heater. It also contains warnings
throughout the manual that you must read and be aware of. All
warnings and all instructions are essential to the proper operation
of the water heater and your safety. Since we cannot put everything
on the first few pages, READ THE ENTIRE MANUAL BEFORE
ATTEMPTING TO INSTALL OR OPERATE THE WATER HEATER.
2. The installation must conform with these instructions and the local
code authority having jurisdiction. In the absence of local codes,
installations shall comply with the National Fuel Gas Code ANSI
Z223.1/NFPA 54. This publication is available from the Canadian
Standards Association, 8501 East Pleasant Valley Rd., Cleveland
Ohio 44131, or The National Fire Protection Association, 1
Batterymarch Park, Quincy, MA 02269.
3. If after reading this manual you have any questions or do not
understand any portion of the instructions, call the local gas utility or
the manufacturer whose name appears on the rating plate.
4. Carefully plan the place where you are going to put the water heater.
Correct combustion, vent action, and vent pipe installation are very
important in preventing death from possible carbon monoxide
poisoning and fires, see Figures 1 and 2.
Examine the location to ensure the water heater complies with the
“Locating the New Water Heater” section in this manual.
5. For California installation this water heater must be braced, anchored,
or strapped to avoid falling or moving during an earthquake. See
instructions for correct installation procedures. Instructions may be
obtained from California Office of the State Architect, 400 P Street,
Sacramento, CA 95814.
6. Massachusetts Code requires this water heater to be installed in
accordance with Massachusetts 248-CMR 2.00: State Plumbing Code
and 248-CMR 5.00.
7. Complies with SCAQMD rule #1121 and districts having equivalent
NOx requirements.
4
TYPICAL INSTALLATION
GET TO KNOW YOUR WATER HEATER - GAS MODELS
A Vent Pipe
B Drafthood
C Anode
D Hot Water Outlet
E Outlet
F Insulation
G Gas Supply
H Manual Gas Shut-off Valve
I Ground Joint Union
* INSTALL IN ACCORDANCE
WITH LOCAL CODES.
* DRIP LEG AS REQUIRED
BY LOCAL CODES.
TO VENT TERMINATION
ON ROOF
J Drip Leg (Sediment Trap)
K Inner Door
L Outer door
M Union
N Inlet Water Shut-off Valve
O Cold Water Inlet
P Inlet Dip Tube
Q Temperature-Pressure Relief Valve
R Rating Plate
S Flue Baffle
T Thermostat
U Drain Valve
V Pilot and Main Burner
W Flue
X Drain Pan
Y Piezo Ignitor
Z Air Intake Screen
ZZ Thermostat Shield (optional)
(V) PILOT & MAIN BURNER
* ALL PIPING MATERIALS TO BE
SUPPLIED BY CUSTOMERS.
(T) THERMOSTAT
FIGURE 1.
5
TYPICAL INSTALLATION
MIXING VALVE USAGE
FIGURE 2.
This appliance has been design certified as complying with American
National Standard/CSA Standard for water heaters and is considered
suitable for:
Water (Potable) Heating and Space Heating: All models are
considered suitable for water (potable) heating and space heating.
HOTTER WATER CAN SCALD:
Water heaters are intended to produce hot water. Water heated to
a temperature which will satisfy space heating, clothes washing,
dish washing, and other sanitizing needs can scald and permanently
injure you upon contact. Some people are more likely to be
permanently injured by hot water than others. These include the
elderly, children, the infirm, or physically/mentally handicapped. If
anyone using hot water in your home fits into one of these groups
or if there is a local code or state law requiring a certain temperature
water at the hot water tap, then you must take special precautions.
In addition to using the lowest possible temperature setting that
satisfies your hot water needs, a means such as a *Mixing Valve,
shall be used at the hot water taps used by these people or at the
water heater. Mixing valves are available at plumbing supply or
hardware stores. Consult a Qualified Installer or Service Agency.
Follow mixing valve manufacturer’s instructions for installation of
the valves. Before changing the factory setting on the thermostat,
read the “Temperature Regulation” section in this manual, see Figures
14 and 15.
6
LOCATING THE NEW WATER HEATER
FACTS TO CONSIDER ABOUT THE LOCATION
Carefully choose an indoor location for the new water heater, because
the placement is a very important consideration for the safety of the
occupants in the building and for the most economical use of the
appliance. This water heater is not for use in manufactured
(mobile) homes or outdoor installation.
Whether replacing an old water heater or putting the water heater in a
new location, the following critical points must be observed:
1. Select a location indoors as close as practical to the gas vent or
chimney to which the water heater vent is going to be connected,
and as centralized with the water piping system as possible.
2. Selected location must provide adequate clearances for servicing
and proper operation of the water heater.
Installation of the water heater must be accomplished in such a manner
that if the tank or any connections should leak, the flow will not cause
damage to the structure. For this reason, it is not advisable to install the
water heater in an attic or upper floor. When such locations cannot be
avoided, a suitable drain pan should be installed under the water heater.
Drain pans are available at your local hardware store. Such a drain
pan must have a minimum length and width of at least 2 inches (51 mm)
greater that the water heater dimensions and must be piped to an
adequate drain. The pan must not restrict combustion air flow.
being ignited, gasoline and other flammable substances should never
be stored or used in the same vicinity or area containing a gas water
heater or other open flame or spark producing appliance.
Also, the water heater must be located and/or protected so it is not
subject to physical damage by a moving vehicle.
Water heater life depends upon water quality, water pressure and the
environment in which the water heater is installed. Water heaters are
sometimes installed in locations where leakage may result in property
damage, even with the use of a drain pan piped to a drain. However,
unanticipated damage can be reduced or prevented by a leak detector
or water shut-off device used in conjunction with a piped drain pan.
These devices are available from some plumbing supply wholesalers
and retailers, and detect and react to leakage in various ways:
• Sensors mounted in the drain pan that trigger an alarm or turn off the
incoming water to the water heater when leakage is detected.
• Sensors mounted in the drain pan that turn off the water supply to
the entire home when water is detected in the drain pan.
• Water supply shut-off devices that activate based on the water
pressure differential between the cold water and hot water pipes
connected to the water heater.
• Devices that will turn off the gas supply to a gas water heater while
at the same time shutting off its water supply.
INSTALLATIONS IN AREAS WHERE FLAMMABLE LIQUIDS
(VAPORS) ARE LIKELY TO BE PRESENT OR STORED (GARAGES,
STORAGE AND UTILITY AREAS, ETC.): Flammable liquids (such as
gasoline, solvents, propane (LP or butane, etc.) and other substances
(such as adhesives, etc.) emit flammable vapors which can be ignited
by a gas water heater’s pilot light or main burner. The resulting flashback
and fire can cause death or serious burns to anyone in the area. Even
though this water heater is a flammable vapors ignition resistant water
heater and is designed to reduce the chances of flammable vapors
This water heater must not be installed directly on carpeting. Carpeting
must be protected by metal or wood panel beneath the appliance
extending beyond the full width and depth of the appliance by at least
3 inches (76.2 mm) in any direction, or if the appliance is installed in an
alcove or closet, the entire floor must be covered by the panel. Failure
to heed this warning may result in a fire hazard.
Minimum clearances between the water heater and combustible
construction are 0 inch at the sides and rear, 4 inches (102 mm) at the
front, and 6 inches (153 mm) from the vent pipe. Clearance from the
top of the jacket is 12 inches (305 mm) on most models. Note that a
lesser dimension may be allowed on some models, refer to the label
attached adjacent to the gas control valve on the water heater, see
Figure 3.
7
FIGURE 3.
A gas water heater cannot operate properly without the correct amount
of air for combustion. Do not install in a confined area such as a closet,
unless you provide air as shown in the “Locating The New Water
Heater” section. Never obstruct the flow of ventilation air. If you have
any doubts or questions at all, call your gas supplier. Failure to provide
the proper amount of combustion air can result in a fire or explosion
and cause death, serious bodily injury, or property damage.
Should you choose to apply an insulation blanket to this heater, you
should follow these instructions (For identification of components
mentioned below, see Figure 1). Failure to follow these instructions
can restrict the air flow required for proper combustion, potentially
resulting in fire, asphyxiation, serious personal injury or death.
• Do not apply insulation to the top of the water heater, as this will
interfere with safe operation of the draft hood.
Do not cover the outer door, thermostat or temperature & pressure
•
relief valve.
FIGURE 4.
If this water heater will be used in beauty shops, barber shops, cleaning
establishments, or self-service laundries with dry cleaning equipment,
it is imperative that the water heater or water heaters be installed so
that combustion and ventilation air be taken from outside these areas.
Propellants of aerosol sprays and volatile compounds, (cleaners,
chlorine based chemicals, refrigerants, etc.) in addition to being highly
flammable in many cases, will also change to corrosive hydrochloric
acid when exposed to the combustion products of the water heater.
The results can be hazardous, and also cause product failure.
Do not allow insulation to come within 2" (50.8 mm) of the floor to
•
prevent blockage of combustion air flow to the burner.
Do not cover the instruction manual. Keep it on the side of the
•
water heater or nearby for future reference.
Do obtain new warning and instruction labels from the manufacturer
•
for placement on the blanket directly over the existing labels.
Do inspect the insulation blanket frequently to make certain it
•
does not sag, thereby obstructing combustion air flow.
COMBUSTION AIR AND VENTILATION FOR
APPLIANCES LOCATED IN UNCONFINED SPACES
UNCONFINED SPACE is space whose volume is not less than
50 cubic feet per 1,000 Btu per hour (4.8 cm per kW) of the aggregate
input rating of all appliances installed in that space. Rooms
communicating directly with the space in which the appliances are
installed, through openings not furnished with doors, are considered a
part of the unconfined space.
In unconfined spaces in buildings, infiltration may be adequate to provide
air for combustion, ventilation and dilution of flue gases. However, in
buildings of tight construction (for example, weather stripping, heavily
insulated, caulked, vapor barrier, etc.), additional air may need to be
provided using the methods described in “Combustion Air and Ventilation
for Appliances Located in Confined Spaces.”
COMBUSTION AIR AND VENTILATION FOR
APPLIANCES LOCATED IN CONFINED SPACES
INSULATION BLANKETS
Insulation blankets are available to the general public for external use
on gas water heaters but are not necessary with these products. The
purpose of an insulation blanket is to reduce the standby heat loss
encountered with storage tank heaters. Your water heater meets or
exceeds the National Appliance Energy Conversation Act standards
with respect to insulation and standby loss requirements, making an
insulation blanket unnecessary.
CONFINED SPACE is a space whose volume is less than 50 cubic feet
per 1,000 Btu per hour (4.8 cm per kW) of the aggregate input rating of
all appliances installed in that space.
A. ALL AIR FROM INSIDE BUILDINGS: (See Figure 4 and 5)
The confined space shall be provided with two permanent openings
communicating directly with an additional room(s) of sufficient volume
so that the combined volume of all spaces meets the criteria for an
8
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