State Water Heaters Standard Residential How to use

RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER
SERVICE HANDBOOK
State Water Heater Technical Training Department
© 2004 Ashland city, TN
1
TABLE OF CONTENTS
Page
Introduction
Terms......................................................... 1
Tools .......................................................... 2
Residential Gas Water Heaters
Guidelines.................................................. 3
Installation.................................................. 5
Operations and Servicing
Construction............................................... 6
Control ....................................................... 6
Burner ........................................................ 7
Normal Operations .................................... 7
Temperature .............................................. 8
Gas ............................................................ 8
Water Flow................................................. 9
Page
Service .....................................................10
Procedures and Conditions .....................11
Multiple Heater Piping.............................. 14
Exhaust Venting Notes ............................ 15
Flammable Vapor Ignition Design …….15
Lint, Dust & Oil Screen…………………16
Flame Arrestor…………………………..17
Thermal Cut Off Switch………………...18
Pilot Burner Assembly………………….19
Sealed Combustion Chamber…………20
Piezo Igniter……………………………..21
Technical Bulletins ……………….. 26
RESIDENTIAL GAS SERVICE HANDBOOK INTRODUCTION
This service handbook is designed to aid in servicing and troubleshooting State Non
Power Vented, Residential Gas water heaters in the field. No duplication or reproduction of this
book may be made without the express written authorization of the manufacturer.
The following text and illustrations will provide you with a step-by-step procedure to
verify proper installation, operation, and troubleshooting procedures. Additional quick reference
data is included to assist you in servicing this product.
The information contained in this handbook is designed to answer commonly faced
situations encountered in the operation of the Residential Gas, non power vented, product line
and is not meant to be all-inclusive. If you are experiencing a problem not covered in this
handbook, please contact the State Water Heater Call Center at 1-800-365-0024 or your local
State Water Heater Service Representative for further assistance. Additional information is also
available on the web site www.Statewaterheaters.com. This handbook contains supplemental
information to the Residential Gas installation instructional manual supplied with the water
heater.
Qualifications
This handbook is intended for use by licensed plumbing professionals and reference should be
made to the instructional manual accompanying the product.

RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER
SERVICE HANDBOOK
State Water Heater Technical Training Department
© 2004 Ashland city, TN
2
Tools Required:
Phillips head screw driver
3/8, 7/16, ¾ inch open end wrenches
3/16 inch Allen wrench
11/16 inch – 6 point – socket – for anode removal
set of marked drill bits
electrical multimeter
gas pressure gauge or monometer
water pressure gauge
thermometer
tubing cutter if pilot tube is to be replaced
hose – to drain tank
container – to measure gallons per minute flow
MISCELLANEOUS INFORMATION
Draw efficiency is the quantity of hot water available to the consumer before the outlet water
temperature decreases 25 degrees F. A 40 gallon water heater will typically provide 70% (28
gallons) of this “usable” hot water. The burner is allowed to operate during this test. Incoming,
cold water mixes the remaining stored water below this 25 degree limitation.
Energy Factor is an indicator of the combined thermal efficiency and standby efficiency of a
water heater. The higher the energy factor, the more efficient the water heater will be.
Recovery rate is the amount of water that is heated to a set temperature, per hour. An
example might be that a water heater has a recovery rate of 30 gallons of water per hour at 80
degree F. (Fahrenheit) temperature rise.
“R” Value is a measure of the resistance of a substance to heat flow.
Thermal efficiency is approximately the amount of generated BTU (British Thermal Units),
which enters the water. A percentage of the total BTU passes out through the vent piping.
Temperature rise is the increase in the temperature from its coldest “inlet” water temperature
to the desired hot (outlet) setting. Typically this is assumed to be 40 degrees entering water;
120 degrees desired stored water or 80 degrees “temperature rise.”
Standby efficiency – the water heater’s ability to contain heat in the tank. A minimum of tank
water heat loss per hour is desired.
Sample: temperature change = Btu/h loss/ square foot of tank surface
“R” value
Water cannot (for all practical purposes) be compressed.
Water expands when it is heated.

RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER
SERVICE HANDBOOK
State Water Heater Technical Training Department
© 2004 Ashland city, TN
3
Water Hammer – is a concussion of moving water against the sides of a containing pipe or
vessel on a sudden stoppage of flow.
EX: 1/2 “copper pipe, 5GPM flow (7.2ft/sec.) – stop. Pressure rise of approximately 412 PSI.
3/4” copper pipe, 5GPM flow (3.3ft/sec) – stop. Pressure rise of approximately 188 PSI
Minerals and gases will separate from water as temperature increases.
Formulas:
Btu (British Thermal Unit) is the heat required to raise 1 pound of water 1F
1 BTU = 252 cal = 0.252 kcal
1 cal = 4.187 Joules
BTU X 1.055 = Kilo Joules
BTU divided by 3,413 = Kilowatts
To convert from Fahrenheit to Centigrade: (° F – 32) times 5/9, or .556, equals degrees C.
One gallon of (120F, 49C) water weighs approximately 8.25 pounds.
Pounds X .45359 = Kilogram
Gallons X 3.7854 = Liters
% of Hot = (Mixed Temp. – Cold) divided by (Hot Temp. – Cold)
% Thermal Efficiency = (GPH X 8.25 X Temp. Rise X 1.0) divided by BTU/H Input
Btu Output = GPH X 8.25 X Temp. Rise X 1.0
GPH = (BTU/H Input X % Eff.) divided by (Temp. Rise X 8.25)
One cubic foot of Natural Gas contains about 1000 BTU of heat.
One “therm”is equal to 100,000 BTU
One cubic foot of Propane Gas contains about 2500 BTU of heat.
One gallon of Propane gas contains about 91,250 BTU of heat.
One pound of Propane gas contains about 21,600 BTU of heat.
One pound of gas pressure is equal to 27.7 inches water column pressure
Inches of Water Column X .036091 = PSI
Inches of Water Column X .073483 = Inches of Mercury (Hg.)