State GS6 75 YRPDT User Manual
Instruction Manual
RESIDENTIAL GAS WATER HEATERS
POWER DIRECT VENTED GAS MODELS
NOT FOR USE IN MANUFACTURED (MOBILE) HOMES
LOW LEAD
CONTENT
• 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
PRINTED 0612 185885-003
WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.
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 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.
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible injury or death.
DANGER indicates an imminently hazardous situation which, if not avoided, will result in injury or death.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in injury or death.
CAUTION indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate
injury.
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not
avoided, could result in property damage.
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.
The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances
known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires businesses to warn of
potential exposure to such substances. This product contains a chemical known to the State of California to cause cancer, birth
defects, or other reproductive harm. This appliance can cause low-level exposure to some of the substances included in the act.
This product is certifi ed to comply with a maximum weighted average of 0.25% lead content as required in some areas.
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.
GENERAL SAFETY
WARNING
FIRE AND EXPLOSION HAZARD
Can result in serious injury or death
Do not store or use gasoline or other
flammable vapors and liquids in the vicinity of this
or any other appliance. Storage of or use of
FLAMMABLES
Flammable Vapors
gasoline or other flammable vapors or liquids in the
vicinity of this or any other appliance can result in
serious injury or death.
Read and follow water heater warnings and instructions.
2
3
TABLE OF CONTENTS
SAFE INSTALLATION, USE AND SERVICE.................................. 2
GENERAL SAFETY.....................................................................2-3
TABLE OF CONTENTS .................................................................. 4
INTRODUCTION ............................................................................ 4
Preparing for the New Installation............................................... 4
INSTALLATION REQUIREMENTS FOR THE
COMMONWEALTH OF MASSACHUSETTS ................................. 5
TYPICAL INSTALLATION ............................................................... 6
MIXING VALVE USAGE ................................................................. 7
LOCATING THE NEW WATER HEATER .................................. 8-11
Facts to Consider About Location ............................................ 8-9
Combustion Air and Exhaust Termination Clearances ........... 9-10
Wire Fence ............................................................................... 10
Air for Ventilation for Appliances Located in Confi ned Spaces .... 10
Insulation Blankets............................................................... 10-11
INSTALLING THE NEW WATER HEATER ............................. 12-22
Water Piping ........................................................................ 12-13
Temperature-Pressure Relief Valve .......................................... 13
Gas Piping ........................................................................... 14-15
Sediment Traps......................................................................... 15
Filling the Water Heater ............................................................ 15
Blower Assembly Installation ............................................... 15-16
Vent Connections to Blower Assembly ..................................... 17
Venting and Installation............................................................. 17
Venting Through an Outside Wall ........................................ 17-18
Venting System Example Installation for All Models ............ 18-19
Vent Pipe Separation ................................................................ 19
Cutting Openings Through an Outside
Wall and Collar Installation ....................................................... 19
Installation Showing Use of PVC, ABS or CPVC Pipe
for Inlet and Outlet Vent Piping ................................................. 19
Connecting Vent to Blower ........................................................... 20
Installation Showing Use of (optional)
Concentric Termination Kit ........................................................ 20
Venting Through a Roof ....................................................... 20-21
Vent Pipe Preparation .......................................................... 21-22
LIGHTING & OPERATING LABEL ............................................... 23
TEMPERATURE REGULATION .................................................. 24
FOR YOUR INFORMATION ......................................................... 25
Start Up Conditions................................................................... 25
Operational Conditions ............................................................. 25
PERIODIC MAINTENANCE ....................................................26-28
Venting System Inspection ....................................................... 26
Burner Operation and Inspection .............................................. 26
Burner Cleaning ........................................................................ 26
Housekeeping ........................................................................... 26
Anode Rod ................................................................................ 27
Temperature-Pressure Relief Valve Operation .................... 27-28
Draining and Flushing ............................................................... 28
Drain Valve Washer Replacement ............................................ 28
Service ...................................................................................... 28
LEAKAGE CHECKPOINTS .......................................................... 29
REPAIR PARTS LIST ................................................................... 30
TROUBLESHOOTING GUIDELINES ...................................... 31-33
WARRANTY ............................................................................34-35
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-fi red water heater is design certifi ed 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 of this manual fi rst 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-fi red 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. 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-current edition and the National Electrical Code,
NFPA 70-current edition. These publications are available from
The National Fire Protection Association, 1 Batterymarch Park,
Quincy, MA 02269.
3. The water heater when installed must be grounded in accordance
with the local codes, or in the absence of local codes: the National
Electrical Code. ANSI/NFPA 70.
4. 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.
5. Carefully plan your placement of the water heater. Correct
combustion, vent action, and vent pipe installation are very
important in preventing death from possible carbon monoxide
poisoning and fi res, 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.
6. For California installation, this water heater must be braced,
anchored, or strapped to avoid falling or moving during an
earthquake. Correct installation procedure instructions may be
obtained from California’s Offi ce of the State Architect, 1102 Q
street, Suite 5100, Sacramento, CA 95811. Instructions can also
be downloaded to your computer at www.dsa.dgs.ca.gov/Pubs.
7. 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. For more information see next page.
8. Complies with SCAQMD rule #1121 and districts having equivalent
NOx requirements.
4
INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS
For all side wall terminated, horizontally vented power vent, direct vent, and power direct vent gas fueled water heaters installed
in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by
the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above fi nished grade in the
area of the venting, including but not limited to decks and porches, the following requirements shall be satisfi ed:
INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas
fueled equipment, the installing plumber or gasfi tter shall observe that a hard wired carbon monoxide detector with an alarm
and battery back-up is installed on the fl oor level where the gas equipment is to be installed. In addition, the installing plumber
or gasfi tter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each
additional level of the dwelling, building or structure served by the sidewall horizontal vented gas fueled equipment. It shall
be the responsibility of the property owner to secure the services of qualifi ed licensed professionals for the installation of hard
wired carbon monoxide detectors.
In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired
carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent fl oor level.
In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall
have a period of thirty (30) days to comply with the above requirements provided that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.
APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above
provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and CSA certifi ed.
SIGNAGE A metal or plastic identifi cation plate shall be permanently mounted to the exterior of the building at a minimum height
of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, “GAS VENT DIRECTLY BELOW.
KEEP CLEAR OF ALL OBSTRUCTIONS.”
INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the
installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance
with the provisions of 248 CMR 5.08(2)(a) 1 through 4.
EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:
1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current edition of NFPA 54
as adopted by the Board; and
2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the
dwelling, building, or structure used in whole or in part for residential purposes.
MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED When the manufacturer of Product
Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with
the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall
include:
1. Detailed instructions for the installation of the venting system design or the venting system components; and
2. A complete parts list for the venting system design or venting system.
MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED When the manufacturer of
a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the fl ue gases,
but identifi es “special venting systems,” the following requirements shall be satisfi ed by the manufacturer:
1. The referenced “special venting system” instructions shall be included with the appliance or equipment installation
instructions; and
2. The “special venting systems” shall be Product Approved by the Board, and the instructions for that system shall include a
parts list and detailed installation instructions.
A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting
instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or
equipment at the completion of the installation.
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TYPICAL INSTALLATION
GET TO KNOW YOUR WATER HEATER - GAS MODELS
A Vent Pipe–Exhaust
B Vent Terminal–Exhaust
C Intake or Combustion Air Pipe
D Intake or Combustion Air Terminal
E Vent Adapter
F Blower Assembly
G Cold Water Inlet
H Inlet Water Shut-off Valve
I Union
* ALL PIPING MATERIALS TO BE SUPPLIED BY CUSTOMERS.
** LOCATED UNDER THE BLOWER ASSEMBLY.
*** NOT PICTURED
J Inlet Dip Tube
K Anode**
L Hot Water Outlet
M Outlet Receptacle (115 VAC)
N Temperature-Pressure Relief Valve
O Flue
P Flue Baffl e Assembly**
Q Insulation
R Rating Plate
S Gas Supply
T Manual Gas Shut-off Valve
U Ground Joint Union
V Sediment Trap (Dirt Leg)
W Drain Valve
X Gas Control Valve/Thermostat
Y Metal Drain Pan
Z Inner Door
AA Outer Door
BB HSI Burner Assembly***
CC FV Sensor Assembly
TYPICAL HOT SURFACE IGNITER & MAIN BURNER
HOT
SURFACE
IGNITER
FLAME
SENSOR
*CAUTION: 115 VAC
CONTROL HARNESS
INSIDE OUTER JACKET
TEMPERATURE INDICATORS
TEMPERATURE ADJUSTMENT BUTTONS
FIGURE 1.
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MIXING VALVE USAGE
SUGGESTED PIPING ARRANGEMENT FOR TOP CONNECTIONS
FIGURE 2.
This appliance has been design certifi ed 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 combination water (potable) heating and
space heating and not suitable for space heating applications only.
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 infi rm, or physically/mentally disabled. If anyone using hot water
in your home fi ts 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 satisfi es your hot water needs, a
means such as a mixing valve should 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 Qualifi ed
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 Figure 31.
7
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 vent terminal or
location to which the water heater vent piping 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.
IMPORTANT:
• Do not install the water heater or venting system in a location that
will exceed 140°F (60°C) ambient temperature.
• Keep combustibles such as boxes, magazines, clothes, etc., away
from the water heater area.
water heater’s hot surface igniter or main burner. The resulting
fl ashback and fi re can cause death, serious burns to anyone in
the area and property damage. This water heater is equipped with
an FV sensor for detecting the presence of fl ammable vapors.
See Figure 3. When the sensor detects those vapors, the unit will
shut down and not operate. Should this happen, please refer to
the troubleshooting guide in this manual. Even though this water
heater is a fl ammable vapors ignition resistant water heater and is
designed to reduce the chances of fl ammable vapors being ignited,
gasoline and other fl ammable substances should never be stored
or used in the same vicinity or area containing a gas water heater
or other open fl ame or spark producing appliance.
FIGURE 3.
Do not expose the FV sensor to cleaning solvents or moisture of
any kind. Doing so may activate the safety system and cause the
unit to shut down. Also, the water heater must be located and/or
protected so it is not subject to physical damage by a moving vehicle.
Installation of the water heater must be accomplished in such a
manner that if the tank or any connections should leak, the fl ow will not
cause damage to the structure. For this reason, it is not advisable to
install the water heater in an attic or upper fl oor. When such locations
cannot be avoided, a suitable metal drain pan should be installed
under the water heater. Metal drain pans are available at your local
hardware store. Such a drain pan must have a minimum length and
width of at least 2” (5.1 cm) greater that the water heater dimensions
and must be piped to an adequate drain. Drain pan depth must allow
for access to the outer doors for servicing the ignitor and burner.
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 metal 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 metal drain pan that trigger an alarm or turn
off the incoming water to the water heater when leakage is detected.
• Sensors mounted in the metal 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 fl ammable vapors which can be ignited by a gas
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” (7.6 cm) in any direction, or if the appliance is installed
in an alcove or closet, the entire fl oor must be covered by the panel.
Failure to heed this warning may result in a fi re hazard.
8
Minimum clearances between the water heater and combustible
construction are 0 inch at the sides and rear, 6” (15.2 cm) from the
front of the jacket, and 12” (30.5 cm) from the top (standard clearance).
If clearances stated on the heater differ from standard clearances,
install water heater according to clearances stated on the heater.
Adequate clearance for servicing this appliance should be considered
before installation, such as changing the anodes, etc.
A minimum clearance of 5” (12.7 cm) from the front of the jacket must
be allowed for access to replaceable parts such as the thermostats,
drain valve and relief valve. Provide 24” (61 cm) front clearance for
servicing and adequate clearance between the jacket top and ceiling
for servicing the fl ue area.
When installing the heater, consideration must be given to proper
location. Location selected should be as close to the wall as
practicable and as centralized with the water piping system as
possible.
FIGURE 5.
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 fl ammable in many cases, will also react to form corrosive
hydrochloric acid when exposed to the combustion products of
the water heater. The results can be hazardous, and also cause
product failure.
COMBUSTION AIR AND EXHAUST TERMINATION
CLEARANCES
Venting Through an Outside Wall - Clearances, see Figure 7.
• 0" clearance for 3" PVC, ABS, or CPVC Schedule 40 piping from
combustible surfaces.
• The location selection must provide clearances for servicing and
proper operation of the water heater, see Figure 6.
FIGURE 4.
Never obstruct the fl ow of ventilation air. See Figure 5. If you have
any doubts or questions at all, call your gas company. Failure to
provide ventilation air can result in a fi re or explosion and can cause
DEATH, SERIOUS BODILY INJURY, OR PROPERTY DAMAGE.
FIGURE 6.
• The venting system must be installed in a manner which allows
inspection of the installation of the venting pipes and joints as
well as periodic inspection after installation as required by the
National Fuel Gas Code ANSI Z223.1.
9
VENT TERMINATION CLEARANCES
.........
FIGURE 7.
WIRE FENCE
When the water heater outlet terminal is low enough to be touched
accidentally, or is accessible to small children, a wire mesh chain link
fence (as shown in Figure 8) may be used. Care should be taken to
maintain adequate ventilation around the outlet terminal. If a chain
link fence is installed, it must not be used as a storage area for items
that may block proper ventilation.
• The vent exhaust outlet and air inlet terminals shall terminate at
least 18" (45.7 cm) above the roof surface, see Figure 9.
FIGURE 9.
AIR FOR VENTILATION FOR APPLIANCES LOCATED IN
CONFINED SPACES
Air for ventilation should be provided if installed in a confi ned space.
Refer to the National Fuel Gas Code, ANSI Z223.1.
FIGURE 8.
Venting Through Roof - Clearances
• 0" clearance for 3" PVC, ABS, or CPVC Schedule 40 piping from
combustible and noncombustible surfaces.
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.
10
Should you choose to apply an insulation blanket to this heater, you
should follow these instructions. (For identifi cation of the components
mentioned in the next column, see Figure 1.) Failure to follow these
instructions can restrict the air fl ow required for proper combustion,
potentially resulting in fi re, 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 water heater.
• Do not cover the outer door, gas control valve/thermostat,
temperature & pressure relief valve or FV Sensor.
• Do not let insulation around the gas water heater get within 8 inches
of the fl oor (access for servicing 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 access to burner.
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