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SERVICE HANDBOOK FOR
STANDARD RESIDENTIAL
FVIR GAS WATER HEATERS
MODELS: GPX, GS6, GSX – SERIES 200/201
GS6, GSX (40-Gallon Short) SERIES 202/203
06/09 316876-000
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SERVICE HANDBOOK Your safety and the safety of others is extremely important in the servicing of this water heater. Many safety- related messages and instructions have been provided in this handbook and on your water heater to warn you and others of a potential hazard. Read and obey all safety messages and instructions throughout this handbook. It is very important that the meaning of each safety message is understood by you and others who service this water heater. The information containe
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Fire or Explosion Harzard Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. Avoid all ignition sources if you smell Natural or LP gas. Do not expose water heater control to excessive gas pressure. Use only gas shown on rating plate. Maintain required clearances to combustibles. Keep ignition sources away from faucets after extended period of non-use. Read instruction manual before installing, using or servicing wa
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TROUBLESHOOTING QUICK REFERENCE IMPORTANT: Before performing any test, check the area around the water heater for any source of a flammable vapor (i.e gasoline, paint thinners, etc.) If any sources are found do not proceed until they are removed. PROBLEM POSSIBLE CAUSE TEST / CORRECTIVE ACTION NO HOT WATER: Insuffi cient Combustion Air or Venting Follow the steps on pp 18 – 19. Always check Issues – combustion chamber thermal and clean the base ring fi lter and the fl ame cut off tripped. arres
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PROBLEM POSSIBLE CAUSE TEST / CORRECTIVE ACTION WATER LEAKAGE: Thermostat does not shut-off Check the Gas Control Valve/Thermostat as described on p. 20-21. Drain valve dripping/leaking Back fl ush to clean- out sediment, replace if necessary Tank Leak Check Leakage Checkpoints described on p. 25. 6
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TABLE OF CONTENTS BASIC INSTALLATION ...................................................................................................................................... 8-16 DRAINING AND FILLING THE WATER HEATER ..................................................................................................17 Draining the Water Heater ................................................................................................................................17 Filling the Water Heater ..
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BASIC INSTALLATION & OPERATION INSTALLATION OF RESIDENTIAL GAS WATER HEATER Water Supply- Cold* Water Exhaust Vent to Shut-Off Ouside of Building See Labels and Valve Installation Instructions *Massachusett: Install and Use & Care Guide a vacuum relief in cold Union for clearances. water line per section 19 MGL 142. Union Expansion Tank Pressurize to Equal Supply Water Pressure* (Relieve water pressure To Fixtures - Hot on the expansion tank before adjusting air pressure.) Tempered Wate
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BASIC INSTALLATION & OPERATION This portion of this handbook applies to the Operations and Servicing of Residential Gas, Tank Type, Water Heaters, which are vented atmospherically and use a thermocouple as their electrical source. Control: There are two gas control valve/thermostat confi gurations available. Both valves have similar control elements such as the Gas Control Knob & Water Temperature Dial. Both valves have high water temperature limit safety. Please note the location of the contr
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BASIC INSTALLATION & OPERATION Burner/Manifold Door Assembly: The burner/manifold assembly consists of several components such as: main burner, burner orifi ce, manifold tube, pilot burner, pilot orifi ce, pilot tube, igniter, and thermocouple. See the fi gure below for the complete list of components. The pilot burner remains on once it is manually lit. When incoming cold water activates the thermostat, gas fl ows to the main burner. The pilot fl ame ignites this gas. The main fl ame burns unt
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BASIC INSTALLATION & OPERATION Energy Cut Off (ECO): A metal tube (Temperature Figure 5 Gas Control Knob Probe) mounted onto the back of the gas control valve/thermostat is immersed inside the tank water. Reset Button The probe acts as a temperature high limit. If water gets excessively hot, an Energy Cut Off (ECO) switch Gas Inlet within the probe opens, interrupting the small electrical Protective Temperature current to the gas valve, and gas fl ow through the Plastic Sleeve Probe cont
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BASIC INSTALLATION & OPERATION Thermostat Operation: Standard residential water heaters use mechanical thermostats. With a mechanical thermostat, a dial setting of 120° F may shut the burner down at a tank temperature between 110° and 130° F. The heater will consistently shut off at this same temperature. For this same reason, water temperature may drop 15° F - 25° F, around the temperature probe, before the main burner is activated. Keep in mind that hot water in the upper part of the tank
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BASIC INSTALLATION & OPERATION Combustion Air Requirements: Table 1: Minimum Square Typical Room BTUH Input Feet with with 8’ Ceiling WARNING 8’ Ceiling 30,000 188 9 x 21 Carbon Monoxide Warning 45,000 281 14 x 20 Water heater must be vented to outdoors. 60,000 375 15 x 25 Vent must be installed by a qualified technician using 75,000 469 15 x 31 the local and state codes or, in the absence of local 90,000 563 20 x 28 and state codes, the National Fuel Gas Code, 105,000 657 20 x 33 ANSI Z2
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BASIC INSTALLATION & OPERATION All Air from Inside the Building: When additional air Minimum Free Area of Permanent Openings for is to be provided to the confi ned area from additional Ventilation and Combustion Air Supply - All Air from room(s) within the building, the total volume of the Outdoors Only. room(s) must be of suffi cient size to properly provide Based on total BTUH input rating for all utilizing the necessary amount of fresh air to the water heater equipment within the confi n
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BASIC INSTALLATION & OPERATION Vent Connectors: 1 SQ. INCH PER 1. Type B, Double wall, U.L. Listed Vent Pipe. 2000 BTUH 100 SQ. INCH MINIMUM (EACH) 2. Single wall Vent Pipe. Maintain the manufacturer’s specifi ed minimum clearance from combustible materials when using type OUTLET CONFINED B double wall vent pipe. SPACE OUTDOOR Vent connectors made of type B, double wall vent AIR DUCTS pipe material may pass through walls or partitions constructed of combustible material if the minimum INLET
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BASIC INSTALLATION & OPERATION The following fi gures are examples of vent pipe system • The connector must be firmly attached and sealed to prevent it from falling out. installations and may or may not be typical for your specifi c application. Consult the “National Fuel Gas • To aid in removing the connector, a thimble or slip Code”, NFPA 54, ANSI Z223.1-current edition and the joint may be used. guidelines set forth by prevailing local codes. • The connector must not extend beyond the inn
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DRAINING AND FILLING THE WATER HEATER F illing the Water Heater D raining the W ater Heater Never use this water heater unless it is completely full of water. To prevent damage, the tank must be fi lled with water. Water must fl ow from the hot water faucet before lighting the water heater. NOTE: The hot water The water heater should be drained if being shut down faucet used should be the one furthest from the water during freezing temperatures. Also, periodic draining heater. and cleanin
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CHECKING THE GAS SUPPLY PRESSURE Checking the Gas Supply Pressure GAS PRESSURE LABEL WHITE RODGERS GAS CONTROL VALVE/THERMOSTAT SHOWN Gas pressure checks are done with flowing gas using GAS a gas pressure gauge capable of reading pressure in PRESSURE inches of water column. GAUGE CONNECTED AT • Supply gas pressure checks are measured before PRESSURE TAP the gas control valve/thermostat and as close to the water heater as possible. • Manifold (main burner) gas pressure is measured at th
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CHECKING FOR SUFFICIENT COMBUSTION AIR OR VENTING ISSUES Draft Test External Inspection & Cleaning of After successfully lighting the water heater, allow the the Base-Ring Filter unit to operate for 15 minutes and check the draft 1. At least annually check the base-ring filter for any hood relief opening for proper draft. Make sure all dust or debris that may have accumulated on the other appliances in the area are operating and all filter screen. NOTE: If the water heater is located do
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TESTING THE THERMOCOUPLE AND GAS CONTROL VALVE/THERMOSTAT IMPORTANT: Before performing any test, check the area around the water heater for any source of a Flammable Vapor (i.e gasoline, paint thinners, etc.) If any sources are found do not proceed until they are removed. Thermocouple Output Test The following test will check the DC voltage generated by the thermocouple when the pilot light is lit. 1. Disconnect the thermocouple from the gas control valve/thermostat as shown in the adjacent f
