State Industries Water Heater 184735 000 User Manual

Instruction Manual

RESIDENTIAL POINT OF USE ELECTRIC

WATER HEATERS

FOR POTABLE WATER

HEATING ONLY

NOT SUITABLE FOR

SPACE HEATING

LISTED

GAMA certification applies to all

residential electric water heaters

with capacities of 20 to 120 gallons.

Input rating of 12 Kw or less.

ALL TECHNICAL AND WARRANTY QUESTIONS:SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS

PURCHASED.IFYOUAREUNSUCCESSFUL,PLEASEWRITETOTHECOMPANYLISTEDONTHERATINGPLATEONTHEWATERHEATER.

KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE

WHEN EVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.

PRINTED IN THE U.S.A 0104

PART NO. 184735-000

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GENERAL SAFETY

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INTRODUCTION

Thank You for purchasing this water heater. Properly installed and

maintained, it should give you years of trouble free service.

This application has been listed as complying with UL Standard for

safety UL174.

Abbreviations Found In This Instruction Manual:

2. The installation must conform with these instructions and the local

code authority having jurisdiction and the requirements of the power

company. In the absence of code requirements follow the current

edition of the NEC, National Electrical Code NFPA-70 which may be

ordered from: National Fire Protection Association, 1 Batterymarch

Park, Quincy, MA 02269.

•

ANSI - American National Standards Institute

ASME - American Society of Mechanical Engineers

GAMA - Gas Appliance Manufacturers Association

NEC - National Electrical Code

3. If after reading this manual you have any questions or do not

understand any portion of the instructions, call the local utility or the

manufacturer whose name appears on the rating plate.

NFPA - National Fire Protection Association

UL - Underwriters Laboratories Inc.

4. Carefully plan the place where you are going to put the water heater.

INSTALLATIONORSERVICEOFTHISWATERHEATERREQUIRES

ABILITY EQUIVALENT TO THAT OF A LICENSED TRADESMAN IN

THE FIELD INVOLVED. PLUMBING AND ELECTRICAL WORK ARE

REQUIRED.

PREPARING FOR THE INSTALLATION

1. Read the “General Safety” section 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,

SERIOUSBODILYINJURYAND/ORPROPERTYDAMAGE.

Examine the location to ensure the water heater complies with the

“Facts to Consider About the Location” 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.

This manual contains instructions for the installation, operation, and

maintenance of the electric 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.

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.

TABLE OF CONTENTS

FOR YOUR INFORMATION .............................................. 13

Thermal Expansion .................................................. 13

Strange Sounds .................................................... 13

Operational Conditions............................................ 13

Smelly Water .......................................................... 13

“Air” in Hot Water Faucets.................................... 13

High Water Temperature Shut Off System .......... 13

PERIODIC MAINTENANCE ....................................... 14-16

Temperature-Pressure Relief Valve Operation ..... 14

Draining ..................................................................... 14

Thermostat Removal/Replacement .................. 14,15

Element Cleaning/Replacement ....................... 15,16

Drain Valve Washer Replacement .......................... 16

SAFE INSTALLATION, USE AND SERVICE ..................... 2

GENERAL SAFETY ............................................................. 3

INTRODUCTION ................................................................ 4

Preparing for the Installation ..................................... 4

TABLE OF CONTENTS ...................................................... 4

TYPICAL INSTALLATION .................................................... 5

MIXING VALVE USAGE ....................................................... 5

LOCATING THE NEW WATER HEATER ........................... 6

Facts to Consider About Location............................. 6

Insulation Blankets..................................................... 6

INSTALLING THE NEW WATER HEATER .....................6-9

Optional Wall Mounting ........................................... 6,7

Water Piping ............................................................. 7,8

Temperature-Pressure Relief Valve ...................... 8,9

Filling the Water Heater ........................................... 10

WIRING DIAGRAMS ......................................................... 10

WIRING ............................................................................. 11

TEMPERATURE REGULATION ....................................... 12

Temperature Adjustment ......................................... 12

Service ....................................................................... 16

LEAKAGE CHECKPOINTS .............................................. 17

TROUBLESHOOTING GUIDELINES .............................. 18

REPAIR PARTS LIST ........................................................ 19

WARRANTY ..............................................................INSERT

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TYPICAL INSTALLATION

INSTALL SUITABLE DRAIN PANS

UNDER HEATERS TO PREVENT

DAMAGE DUE TO LEAKAGE.

REFER TO WATER HEATER

LOCATION ON PAGE 8.

INSTALL VACUUM RELIEF IN

COLD WATER INLET LINE AS

REQUIRED BY LOCAL CODES.

INSTALL THERMAL EXPANSION

TANK OR DEVICE IF WATER

HEATER IS INSTALLED IN A

CLOSED WATER SYSTEM.

FIGURE 1.

MIXING VALVE USAGE

Water (Potable) Heating: All models are considered suitable for

water (potable) heating only.

contractor. 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.

HOTTERWATERCANSCALD:

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 local plumbing

FIGURE 2.

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LOCATING THE NEW WATER HEATER

damage to the structure. For this reason, it is not advisable to install the

FACTS TO CONSIDER ABOUT THE LOCATION

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 from your local plumbing contractor. 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.

Also, the water heater must be located and/or protected so it is not

subject to physical damage by a moving vehicle.

INSULATION BLANKETS

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.

Insulation blankets are available to the general public for external use

on electric water heaters but are not necessary with this product. 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.

Whether replacing an old water heater or putting the water heater in a

new location, the following critical points must be observed:

Should you choose to apply an insulation blanket to this heater, you

should follow these instructions below. Failure to follow these

instructions can result in fire, serious personal injury, or death.

1. Select a location indoors as close as practical or centralized to the

water piping system as possible. The water heater should be

located in an area not subject to freezing temperatures.

•

Do not cover the temperature and pressure relief (T & P) valve with

an insulation blanket.

2. Selected location must provide adequate clearances (4”) for servicing

parts such as the thermostats, drain valve and relief valve. Adequate

clearance for servicing this appliance should be considered before

installation, such as changing the anodes, etc.

Do not cover the instruction manual. Keep it on the side of the

water heater or nearby for future reference.

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

Do obtain new warning and instruction labels for placement on the

blanket directly over the existing labels.

INSTALLING THE NEW WATER HEATER

WALL CONSTRUCTION AT THE POINT OF THE WATER HEATER

INSTALLATION MUST BE CAPABLE OF SUPPORTING AT LEAST 200

POUNDS.

OPTIONAL WALL MOUNTING

As an example: if the water heater is to be installed on a wall of

gypsum board (dry wall) or other material not capable of supporting

the water heater filled with water, additional bracing will be necessary.

Two possibilities are shown, see Figure 3.

1. Using two sheet metal screws supplied, secure the top mounting

bracket to the top of the water heater.

FIGURE4.

2. Using the remaining two sheet metal screws provided, secure the

bottom mounting bracket to the bottom of the water heater.

FIGURE3.

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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, cleaning 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. Valves for reducing

point of use temperature by mixing cold and hot water are also available.

Consult a Qualified Installer or Service Agency. Follow manufacturer’s

instructions for installation of the valves. Before changing the factory

setting on the thermostat, read the “Temperature Regulation” section in

this manual.

FIGURE5.

3. Determine the location on the wall, and then the height above the

floor which the wall securing bracket will be placed. Using adequate

screws, or nuts, and bolts (not supplied) fasten the wall securing

bracket to the wall.

This water heater shall not be connected to any heating systems or

component(s) used with a non-potable water heating appliance.

Toxic chemicals, such as those used for boiler treatment shall not be

introduced into this system.

Water supply systems may, because of such events as high line

pressure, frequent cut-offs, the effects of water hammer among

others, have installed devices such as pressure reducing valves, check

valves, back flow preventers, etc. to control these types of problems.

When these devices are not equipped with an internal by-pass, and no

other measures are taken, the devices cause the water system to be

closed. As water is heated, it expands (thermal expansion) and closed

systems do not allow for the expansion of heated water.

The water within the water heater tank expands as it is heated and

increases the pressure of the water system. If the relieving point of

the water heater’s temperature-pressure relief valve is reached, the

valve will relieve the excess pressure. The temperature-pressure

relief valve is not intended for the constant relief of thermal

expansion. This is an unacceptable condition and must be corrected.

It is recommended that any devices installed which could create a

closed system have a by-pass and/or the system have an expansion

tank or device to relieve the pressure built by thermal expansion in the

water system. Expansion tanks are available for ordering through a

local plumbing contractor. Contact the local water supplier and/or a

service agency for assistance in controlling these situations.

FIGURE6.

WATER PIPING

NOTE: To protect against untimely corrosion of hot and cold

water fittings, it is strongly recommended that di-electric

unions or couplings be installed on this water heater when

connected to copper pipe.

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If replaced, the valve must meet the requirements of local codes, but

not less than a combination temperature and pressure relief valve

certified as indicated in the above paragraph.

Figure 7 shows the typical attachment of the water piping to the water

heater. The water heater is equipped with 3/4 inch NPT water

connections.

The valve must be marked with a maximum set pressure not to exceed

the marked hydrostatic working pressure of the water heater

(150 psi = 1,035 kPa) and a discharge capacity not less than the water

heater input rate as shown on the model rating plate.

NOTE: If using copper tubing, solder tubing to an adapter

before attaching the adapter to the cold water inlet connection.

Do not solder the cold water supply line directly to the cold

water inlet, it will harm the dip tube and damage the tank.

For safe operation of the water heater, the relief valve must not be

removed from its designated opening nor plugged.

The temperature-pressure relief valve must be installed directly into

the fitting of the water heater designed for the relief valve. Position the

valve downward and provide tubing so that any discharge will exit

only within 6 inches (153 mm) above, or at any distance below the

structural floor. Be certain that no contact is made with any live electrical

part. The discharge opening must not be blocked or reduced in size

under any circumstances. Excessive length, over 30 feet (9.14 m), or

use of more than four elbows can cause restriction and reduce the

discharge capacity of the valve.

No valve or other obstruction is to be placed between the relief valve

and the tank. Do not connect tubing directly to discharge drain unless

a 6 inch air gap is provided. To prevent bodily injury, hazard to life, or

property damage, the relief valve must be allowed to discharge water

in quantities should circumstances demand. If the discharge pipe is not

connected to a drain or other suitable means, the water flow may

cause property damage.

FIGURE 7.

The Discharge Pipe:

TEMPERATURE-PRESSURE RELIEF VALVE

• Shall not be smaller in size than the outlet pipe size of the valve, or

have any reducing couplings or other restrictions.

• Shall not be plugged or blocked.

• Shall be of material listed for hot water distribution.

• Shall be installed so as to allow complete drainage of both the

temperature-pressure relief valve, and the discharge pipe.

• Shall terminate at an adequate drain.

• Shall not have any valve between the relief valve and tank.

This heater is provided with a properly certified combination

temperature - pressure relief valve by the manufacturer.

The valve is certified by a nationally recognized testing laboratory that

maintains periodic inspection of production of listed equipment of

materials as meeting the requirements for Relief Valves and Automatic

Gas Shut-off Devices for Hot Water Supply Systems, ANSI Z21.22 •

CSA 4.4, and the code requirements of ASME.

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The temperature-pressure relief valve must be manually operated at

least once a year. Caution should be taken to ensure that (1) no one is

in front of or around the outlet of the temperature-pressure relief valve

discharge line, and (2) the water manually discharged will not cause

any bodily injury or property damage because the water may be

extremely hot.

If after manually operating the valve, it fails to completely reset and

continues to release water, immediately close the cold water inlet to

the water heater, follow the draining instructions, and replace the

temperature-pressure relief valve with a new one.

FILLING THE WATER HEATER

Never use this water heater unless it is completely full of water. To

prevent damage to the tank, the tank must be filled with water. Water

must flow from the hot water faucet before turning “ON” electrical

supply to the water heater.

To fill the water heater with water:

1. Close the water heater drain valve by turning the handle to the right

(clockwise). The drain valve is on the lower front of the water

heater.

2. Open the cold water supply valve to the water heater.

NOTE: The cold water supply valve must be left open when

the water heater is in use.

3. To insure complete filling of the tank, allow air to exit by opening the

nearest hot water faucet. Allow water to run until a constant flow

is obtained. This will let air out of the water heater and the piping.

FIGURE 8.

4. Check all water piping and connections for leaks. Repair as needed.

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WIRING DIAGRAMS

TURN OFF THE HEATER ELECTRICAL SUPPLY BEFORE SERVICING ANY ELECTRICAL COMPONENTS.

OPTIONAL CORD SET WIRING (120 Volt and 240 Volt)

There may be a cord set supplied with the water heater

at the time of manufacture. If not one can be ordered

through the Parts Department; see “Repair Parts List”

section. Refer to Figure 9 for wiring diagrams.

120 VOLT WIRING

240 VOLT WIRING

FIGURE 9.

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WIRING

1. Provide a way to easily shut off the electric power when working

on the water heater. This could be with a circuit breaker or fuse

block in the entrance box or a separate disconnect switch.

2. Install and connect a circuit directly from the main fuse or circuit

breaker box. This circuit must be the right size and have its own

fuse or circuit breaker.

3. If metal conduit is used for the grounding conductor:

A. The grounding electrode conductor shall be of copper, aluminum,

or copperclad aluminum. The material shall be of one continuous

length without a splice or joint.

Never use water heater unless it is completely full of water. To prevent

damage to the tank and heating element, the tank must be filled with

water. Water must flow from the hot water faucet before turning on

power.

B. Rigid metal conduit, intermediate metal conduit, or electrical,

metallic tubing may be used for the grounding means if conduit or

tubing is terminated in fittings approved for grounding.

You must provide all wiring of the proper size outside of the water

heater. You must obey local codes and electric company requirements

when you install this wiring.

C. Flexible metal conduit or flexible metallic tubing shall be permitted

for grounding if all the following conditions are met:

If you are not familiar with electric codes and practices, or if you have

any doubt in your ability to connect the wiring to this water heater,

obtain the service of a competent electrician. Contact a local electrical

contractor and/or the local electric utility.

•

The length in any ground return path does not exceed 6 feet.

The circuit conductors contained therein are protected by

overcurrent devices rated at 20 amperes or less.

•

The conduit or tubing is terminated in fittings approved for

grounding.

For complete grounding details and all allowable exceptions, refer to

the current edition of the NEC, National Electrical Code NFPA 70.

4. A standard 1/2” conduit opening has been made in the water heater

junction box for the conduit connections.

5. Use wire nuts and connect the power supply wiring to the wires

inside the water heater’s junction box.

6. The water heater must be electrically “grounded” by the installer. A

green ground screw has been provided on the water heater’s

junction box. Connect ground wire to this location.

7. Replace the wiring junction cover using the screw provided.

WATER HEATERS EQUIPPED FOR ONE VOLTAGE ONLY: This water

heater is equipped for one type voltage only. Check the rating plate

near the bottom access panel for the correct voltage. DO NOT use this

water heater with any voltage other than the one shown on the model

rating plate. Failure to use the correct voltage can cause problems

which can result in DEATH, SERIOUS BODILY INJURY, OR PROPERTY

DAMAGE. If you have any questions or doubts consult your electric

company.

If wiring from your fuse box or circuit breaker box was aluminum for

your old water heater, replace it with copper wire. If you wish to reuse

the existing aluminum wire, have the connection at the water heater

made by a competent electrician. Contact a local electrical contractor

and/or the local electric utility.

FIGURE 10.

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TEMPERATURE REGULATION

Due to the nature of the typical water heater, the water temperature in

certain situations may vary up to 30°F (16.7 °C) higher or lower at the

point of use such as, bathtubs, showers, sink, etc.

TEMPERATURE ADJUSTMENT

Any water heater’s intended purpose is to heat water. Hot water is

needed for cleansing, cleaning, and sanitizing (bodies, dishes, clothing).

Untempered hot water can present a scald hazard. Depending on the

time element, and the people involved (adults, children, elderly, infirm,

etc.) scalding may occur at different temperatures.

To change the temperature setting:

NOTE:

1. Turn off the heater electrical supply. Do not attempt to adjust

thermostat with power on.

2. Remove the thermostat outer door and fold away the insulation

from the thermostat. Do not remove the plastic personnel protector

covering the thermostat.

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 from your local plumbing

contractor. Follow manufacturer’s instructions for installation of the

valves. Before changing the factory setting on the thermostat, read

the “Temperature Regulation” section in this manual.

3. Using a flat tip screwdriver, rotate the adjustment knob to the desired

temperature setting.

4. Fold the insulation back in place, replace the outer door and turn on

heater electrical supply.

LO - Setting, approximately 95°F (35°C)

is recommended for vacations or

extended periods of no hot water.

THIS WATER HEATER IS EQUIPPED WITH AN ADJUSTABLE

THERMOSTAT TO CONTROL WATER TEMPERATURE. HOT

WATER TEMPERATURES DESIRED FOR AUTOMATIC

DISHWASHERANDLAUNDRYUSECANCAUSESCALDSRESULTING

IN SERIOUS PERSONAL INJURY AND/OR DEATH.

THETEMPERATUREATWHICHINJURYOCCURSVARIES WITHTHE

PERSON’S AGE AND THE TIME OF THE EXPOSURE. THE SLOWER

RESPONSE TIME OF CHILDREN, AGED OR DISABLED PERSONS

INCREASES THE HAZARDS TO THEM. NEVER ALLOW SMALL

CHILDREN TO USE A HOT WATER TAP, OR TO DRAW THEIR OWN

BATH WATER. NEVER LEAVE A CHILD OR DISABLED PERSON

UNATTENDEDINABATHTUBORSHOWER.

HI - Is setting for the maximum hot water

usage approximately 140°F (60°C),

which can be supplied by the water

heater.

TEMPERATURE SETTINGS

It is recommended that lower water temperatures be used to avoid the

risk of scalding. It is further recommended, in all cases, that the water

temperature thermostat be set for the lowest temperature which

satisfies your hot water needs, see Figure 11. This will also provide

the most energy efficient operation of the water heater. The Thermostat

has been factory set between LO an HI which approximates 120°F

(49°C) unless specified differently by state requirements.

It is recommended that the dial be set lower whenever possible.

Temperature

Setting

Time to Produce 2nd & 3rd

Degree Burns on Adult Skin

160°F (71°C)

150°F (66°C)

140°F (60°C)

130°F (54°C)

120°F (49°C)

About 1/2 second

About 1-1/2 seconds

Less than 5 seconds

About 30 seconds

More than 5 minutes

KEEPINGTHETHERMOSTATSETTINGAT120°F(49°C)WILLREDUCE

THERISKOFSCALDS.

Figure 11 shows the approximate time-to-burn relationship for normal

adult skin.

FIGURE 11.

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FOR YOUR INFORMATION

bleach as needed. On systems where the odor is mild and does not

THERMALEXPANSION

occur too rapidly, a monthly flushing may be sufficient. In more severe

cases, a system feeder would be more appropriate.

“AIR” IN HOT WATER FAUCETS

Water supply systems may, because of such events as high line

pressure, frequent cut-offs, the effects of water hammer among

others, have installed devices such as pressure reducing valves, check

valves, back flow preventers, etc. to control these types of problems.

When these devices are not equipped with an internal by-pass, and no

other measures are taken, the devices cause the water system to be

closed. As water is heated, it expands (thermal expansion) and closed

systems do not allow for the expansion of heated water.

HYDROGEN GAS: Hydrogen gas can be produced in a hot water

system that has not been used for a long period of time (generally two

weeks or more). Hydrogen gas is extremely flammable and explosive.

To prevent the possibility of injury under these conditions, we

recommend the hot water faucet, located farthest away, be opened

for several minutes before any electrical appliances which are

connected to the hot water system are used (such as a dishwasher or

washing machine). If hydrogen gas is present, there will probably be

an unusual sound similar to air escaping through the pipe as the hot

water faucet is opened. There must be no smoking or open flame near

the faucet at the time it is open.