State Water Heaters GP650 HTPDT, Service Handbook

Page 1: ...ERVICING SHOULD ONLY BE PERFORMED BY A QUALIFIED SERVICE AGENT 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 500 Tennessee Waltz Parkway Ashland City TN 37015 ...

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Page 10: ...NECTION CONDENSATE DRAIN CONNECTION BLOCKED EXHAUST SWITCH SENSING TUBE HEATING LOOP SUPPLY LINE CONNECTION 3 4 INCH NPT 2 INCH PVC INTAKE AIR CONNECTION TOP COVER ON OFF SWITCH UIM user interface module CONTROL INTERFACE COVER TEMPERATURE PROBE LOCATED BEHIND CONTROL INTERFACE COVER TANK GLASSING PLUG COVER USED FOR MANUFACTURING PURPOSES ONLY DO NOT REMOVE GLASSING PLUG FOR ANY SERVICE OR MAINTE...

Page 11: ...R 2 INCH PVC INTAKE AIR CONNECTION 2 INCH PVC VENT CONNECTION JUNCTION BOX 120 VAC POWER SUPPLY CONNECTIONS SECOND ANODE ROD LJXUH COMBUSTION BLOWER BURNER ASSEMBLY COMBUSTION BLOWER EXPLODED VIEW GASKET SILICONE BLOWER DISCHARGE ORIFICE GASKET FIBER BURNER SIGHT GLASS AND WIRING HARNESS COVER PLATE GASKET SILICONE GASKET GASKET FIBER GASKET FIBER BURNER SIGHT GLASS BURNER ADAPTER BURNER ADAPTER W...

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Page 15: ...ICE IN PLACE BURNER ADAPTER WIRING HARNESS IGNITER FLAME SENSOR LJXUH BURNER SIGHT GLASS BURNER ADAPTER WIRING HARNESS IGNITER FLAME SENSOR BLOWER DISCHARGE ORIFICE BLOWER FLANGE WITH ORIFICE REMOVED LJXUH BLOWER DISCHARGE ORIFICE BLOWER FLANGE WIRING HARNESS GROMMET BURNER ADAPTER BURNER ADAPTER WIRING HARNESS IGNITER FLAME SENSOR LJXUH ...

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Page 20: ...RROV 5HTXLUHG RQ SDJH IGNITER BURNER FLAME BURNER MUST BE GROUNDED CERAMIC INSULATOR FLAME SENSOR METAL CONDUCTOR CONTROL SYSTEM APPLIES AC VOLTAGE TO FLAME SENSOR AC VOLTAGE FLOWS FROM THE FLAME SENSOR TO THE BURNER THE BURNER MUST BE GROUNDED FOR CURRENT TO FLOW DURING THIS PROCESS THE AC VOLTAGE IS RECTIFIED AND BECOMES A DC VOLTAGE DC MICRO AMP CURRENT THEN FLOWS BETWEEN THE FLAME SENSOR AND T...

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Page 42: ...RZHU WR WKH ZDWHU KHDWHU LV WXUQHG RII 2 5HPRYH WKH VFUHZV WKDW KROG WKH WRS FRYHU LQ SODFH 3 5HPRYH WKH FRYHU VFUHZV IURP WKH 4 6ZLQJ WKH FRYHU DZD IURP WKH HQFORVXUH IURP OHIW VLGH DQG GLVHQJDJH WKH PROGHG FOLSV RQ WKH ULJKW RYHU 5HSODFHPHQW 3URFHGXUH 5HIHU WR LJXUH EHORZ DQG LJXUH RQ SDJH IRU WKHVH LQVWUXFWLRQV 1 5RXWH DOO ZLULQJ DQG FDEOHV VLGH E VLGH ÀDW DFURVV WKH WUDQVIRUPHU FRYHU QVXUH WKH...

Page 43: ...pswitch 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 ...

Page 44: ...VAC neutral 0DOH 6SDGH RQQHFWRU ODPH 6HQVRU 6RFNHW JQLWHU 9 6 KRW VXUIDFH LJQLWHU PIN DESCRIPTION 1 9 KRW 2 120 VAC neutral 6RFNHW 9ROW DV 9DOYH 3UHVVXUH 6ZLWFKHV QDEOH LVDEOH LUFXLW PIN DESCRIPTION 1 1RW XVHG 2 DV YDOYH 9 RXWSXW UHFWL HG WR 9 DW WKH JDV YDOYH ZLULQJ KDUQHVV SOXJ HQG 3 1RW XVHG 4 ORFNHG QWDNH LU VZLWFK 5 ORFNHG KDXVW VZLWFK 6 ORZHU 3URYHU VZLWFK 7 ORZHU 3URYHU VZLWFK 8 QDEOH GLVDE...

Page 45: ...HUJ FXW RXW 9 UHWXUQ UHG ZLUH 3RUW RPPXQLFDWLRQ 3RUW 1RW 8VHG 6RFNHW 1RW 8VHG 3RUW RPPXQLFDWLRQ 3RUW 1RW 8VHG J13 Socket Blower Speed Control PIN DESCRIPTION 1 1RW XVHG 2 1RW XVHG 3 7R SLQ 3 0 ZLULQJ VRFNHW RQ RPEXVWLRQ ORZHU VHH LJXUH RQ SDJH 4 1RW XVHG 5 1RW XVHG 6 1RW XVHG 7 7R SLQ 3 0 ZLULQJ VRFNHW RQ RPEXVWLRQ ORZHU VHH LJXUH RQ SDJH 8 7R SLQ 3 0 ZLULQJ VRFNHW RQ RPEXVWLRQ ORZHU VHH LJXUH RQ ...

Page 46: ...ITE M USER INTERFACE MODULE I U 2 15 4 14 5 10 6 7 8 11 L N 1 4 5 3 WHITE GREEN 7 WHITE BLUE 8 WHITE BROWN 2 RED GREEN WHITE N O I T C N U J X O B N E E R G N E E R G ENABLE DISABLE CIRCUIT JUMPER WIRE BETWEEN PINS 8 AND 11 ON J6 PLUG NOTE COMBUSTION BLOWER ASSEMBLY CONSISTS OF MOTOR BLOWER AND INTEGRAL BLOWER SPEED CONTROL PWM Pulse Width Modulation SPEED INSTRUCTION SIGNAL WIRES FROM CCB TO BLOW...

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Page 50: ...ZDWHU KHDWHU PXVW EH F FOHG RII DQG RQ WR UHVHW WKH RQWURO 6 VWHP NOTE FOLQJ SRZHU ZLOO QRW UHVHW WKH RQWURO 6 VWHP LI WKH FRQGLWLRQ WKDW FDXVHG WKH DXOW KDV QRW EHHQ FRUUHFWHG CONTROL SYSTEM MENUS URP WKH HVNWRS 6FUHHQ SUHVVLQJ WKH 2SHUDWLRQDO EXWWRQ GLUHFWO EHORZ 0HQX RQ WKH ZLOO GLVSOD WKH 0DLQ 0HQX 7KLV LV ZKHUH DOO RQWURO 6 VWHP PHQXV DUH ORFDWHG 7KH WDEOH EHORZ GHVFULEHV WKH RQWURO 6 VWHP PH...

Page 51: ... RQWURO 6 VWHP PHQXV IURP WKH 0DLQ 0HQX LWK 7HPSHUDWXUHV PHQX VHOHFWHG KLJKOLJKWHG LQ EODFN LQ WKH 0DLQ 0HQX VFUHHQ SUHVV WKH 2SHUDWLRQDO XWWRQ XQGHU 6 7 WR HQWHU WKH 7HPSHUDWXUHV PHQX I WKH 7HPSHUDWXUHV PHQX LV QRW VHOHFWHG XVH WKH 8S DQG RZQ XWWRQV WR VHOHFW WKLV PHQX LWHP Temperatures Heater Status Display Settings Heater Information Current Fault SELECT BACK HELP Main Menu LWK WKH 2SHUDWLQJ 6H...

Page 52: ...QX 6WDWXV GLVSOD V WKH FXUUHQW 2SHUDWLQJ 6WDWH VHH 7DEOH RQ SDJH IRU D GHVFULSWLRQ RI WKH YDULRXV RSHUDWLRQDO VWDWHV ECO Contact Blocked Inlet PS ORFNHG 2XWOHW 36 Blower Prover PS GLVSOD V WKH FXUUHQW VWDWH RI WKH VZLWFK FRQWDFWV RSHQ RU FORVHG Blower Low On Blower High On GLVSOD V ZKHWKHU WKH RPEXVWLRQ ORZHU LV UXQQLQJ DW KLJK VSHHG GXULQJ 3UH 3RVW SXUJH DQG WKH HDWLQJ RSHUDWLQJ VWDWHV RU WKH RPE...

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Page 55: ...G WKURXJK WKLV PHQX LWHP Show Contact Information Yes Change Contact Name Change Contact Phone Current Contact Info 000 000 0000 Access Code UPDATE CANCEL Service Contact Information 8VLQJ WKH 83 DQG 2 1 EXWWRQV VHOHFW KLJKOLJKWHG LQ EODFN WKH KDQJH RQWDFW 1DPH PHQX LWHP 3UHVV WKH 2SHUDWLRQDO XWWRQ XQGHU 6 7 WR RSHQ WKH KDQJH RQWDFW 1DPH PHQX Show Contact Information Yes Change Contact Name Change...

Page 56: ...LWFK FRQWDFWV DUH FRQ UPHG FORVHG WKH RQWURO 6 VWHP HQHUJL HV WKH JQLWHU IRU WKH JQLWHU DUP 8S RSHUDWLQJ VWDWH 6HH 2SHUDWLQJ 6WDWHV RQ SDJH 8 7KH RQWURO 6 VWHP PRQLWRUV JQLWHU FXUUHQW DQG PXVW VHQVH D PLQLPXP RI DPSV GXULQJ WKH JQLWHU DUP 8S RSHUDWLQJ VWDWH I PLQLPXP FXUUHQW LV QRW VHQVHG WKH RQWURO 6 VWHP ZLOO ORFN RXW DQG GLVSOD WKH Low Igniter Current IDXOW PHVVDJH RQ WKH 9 I JQLWHU FXUUHQW LV ...

Page 57: ... 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 Control System Locks Out Displays Fault Msg Combustion Blower is energized Pre Purge cycle YES Does Control System sense minimum 0 5 AC amps through the Igniter YES Control System Locks Out Blower Prover Open Fault Msg is displayed NO Control System Locks Out Low...

Page 58: ...QWDFWV IRU WKH ORZHU 3URYHU ORFNHG QWDNH LU DQG ORFNHG KDXVW VZLWFKHV 7KLV LQIRUPDWLRQ LV GLVSOD HG LQ UHDO WLPH 8VH WKLV PHQX ZKHQ WURXEOHVKRRWLQJ WR TXLFNO DQG DFFXUDWHO GLDJQRVH RSHUDWLRQDO SUREOHPV THINGS TO CHECK BEFORE SERVICING 8VLQJ WKH QVWUXFWLRQ 0DQXDO WKDW FDPH ZLWK WKH ZDWHU KHDWHU DV UHIHUHQFH YHULI WKH ZDWHU SLSLQJ JDV OLQH YHQWLQJ DQG HOHFWULFDO KDYH DOO EHHQ SURSHUO LQVWDOOHG QVXUH...

Page 59: ... FRQQHFWLRQV DW 8 0 V 6RFNHW SDJH 8 0 8VHU QWHUIDFH 0RGXOH RQ SDJH DQG WKH V 6RFNHW SDJH 6HFXUH SRZHU DQG LQVWDOO D QHZ FRPP FDEOH VWDQGDUG DW QHWZRUN FDEOH ORVHO LQVSHFW FRPPXQLFDWLRQ SRUWV RQ DQG 8 0 IRU GDPDJH RU ZHDU QVXUH 9 LV VXSSOLHG WR V 6RFNHW SLQV RW ZLUH WR SLQ QHXWUDO ZLUH WR SLQ SDJH KHFN 9 WR WUDQVIRUPHU SULPDU ZLQGLQJ DW V VRFNHW SLQV SDJH ZLWK SOXJ UHPRYHG SRZHU RQ KHFN SOXJ DQG VR...

Page 60: ...LQHG KHUH 7HPS 3UREH 2SHQ 7KH RQWURO 6 VWHP KDV GHWHFWHG PRUH WKDQ RKPV IURP WKH 7HPSHUDWXUH 6HQVRU LQVLGH WKH 7HPSHUDWXUH 3UREH CHANGE BACK ADVANCED 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 KHFN 7HPSHUDWXUH 3UREH SOXJ DQG VRFNHW FRQQHFWLRQ DW V 6RFNHW SDJH 3HUIRUP FORVH YLVXDO LQV...

Page 61: ...XVW JDS EHWZHHQ WKH ODPH 6HQVRU DQG WKH XUQHU DOO WKH WROO IUHH VXSSRUW SKRQH QXPEHU RQ WKH EDFN FRYHU RI WKLV PDQXDO IRU IXUWKHU DVVLVWDQFH LI WKH SUREOHP KDV QRW EHHQ FRUUHFWHG DIWHU SHUIRUPLQJ WKH SURFHGXUHV RXWOLQHG KHUH ODPH HWHFW UURU 7KH RQWURO 6 VWHP KDV GHWHFWHG ÀDPH VHQVLQJ FXUUHQW RXW RI VHTXHQFH CHANGE BACK ADVANCED Flame Detect Error Fault occurred 2 mins ago Flame detected out of seq...

Page 62: ...O IRU IXUWKHU DVVLVWDQFH DO NOT LEAVE THE WATER HEATER IN OPERATION UNDER ANY 5 8067 1 6 I UHFRUGHG WHPSHUDWXUH IURP DERYH LV EHORZ F FOH SRZHU WR UHVHW WKH RQWURO 6 VWHP DWFK WKH ZDWHU KHDWHU WKURXJK VHYHUDO KHDWLQJ F FOHV I WDQN WHPSHUDWXUH FOLPEV DERYH WKH FXUUHQW 2SHUDWLQJ 6HW 3RLQW E PRUH WKDQ VKXW RII SRZHU DQG JDV WR WKH ZDWHU KHDWHU DQG FDOO WKH WROO IUHH VXSSRUW SKRQH QXPEHU RQ WKH EDFN F...

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Page 69: ...NOTES ...

Page 70: ...NOTES ...

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