State Industries 540A, 650A, 740A Troubleshooting, Water is TOO HOT, Water Heater Makes Sounds

2.Check the fuses.

•The electrical disconnect switch usually contains fuses.

3.The capacity of the heater may have been exceeded by a large demand for hot water.

4.Colder incoming water temperature will lengthen the time required to heat water to the desired temperature.

•If the heater was installed when incoming water temperature was warm, colder water creates the effect of less hot water.

5.Look for hot water wastage and leaking or open hot water faucets.

6.Sediment or lime scale may be affecting water heater operation. Refer to MAINTENANCE for details.

7.Heater or burner may be dirty.

•Clean all heater flue pipes and flue connector, see

MAINTENANCE.

•Have burner properly cleaned and readjusted.

8.Burner may not be firing at proper rate.

•Check gas pressure

9.Burner fan wheel may be dirty.

•Clean fan wheel with a soft brush.

10.Reset button on high limit control (Figure 1) has operated. Press reset button.

WATER IS TOO HOT

1.Refer to WATER TEMPERATURE CONTROL.

WATER HEATER MAKES SOUNDS

1.Sediment or lime scale accumulation cause rumbling and pounding noises when the heater is operating.

•The sounds are normal, however, the tank bottom should be cleaned. Refer to MAINTENANCE for details.

2.Some of the electrical components of the water heater make sounds which are normal.

•Contacts click or snap as the heater starts and stops.

•Transformers often hum.

WATER LEAKAGE IS SUSPECTED

1.Check to see if the water heater drain valve is tightly closed. Also check the cleanout opening for leakage.

2.The apparent leakage may be condensation that forms on cool surfaces of the heater and piping.

3.If the outlet of the relief valve is leaking it may represent:

•Excessive water pressure

•Excessive water temperature

•Faulty relief valve

Excessive water pressure is the most common cause of relief valve leakage. It is often caused by a “closed system”. If a check valve, back flow preventer, or pressure-reducing valve is in the inlet system it will not permit the expanded hot water volume to equalize pressure with the main. The relief valve must release this water or the water heater or plumbing system will be damaged. Refer to MAINTENANCE – RELIEF VALVES.

When such a condition is encountered, local codes or inspection agency should be consulted to determine which system is acceptable in your area. These may consist of:

•Installation of a second relief valve with lower setting than the primary relief valve.

•An expansion tank of suitable size and pressure rating and provision to avoid water logging.

HOT WATER ODOR

On occasion, hot water may develop a strong odor. If this occurs, drain the heater completely, flush thoroughly, and refill. If the problem persists, chlorinating of the heater and replacement of the factory installed magnesium anodes with aluminum anodes may correct the condition.

Occasionally water softener companies recommend removal of heater anodes for odor reasons.

CAUTION

Unauthorized removal of the anode(s) will void the warranty. For further information contact your dealer.

TROUBLESHOOTING

WARNING

JUMPING OUT COMPONENTS AND/OR CIRCUITS DURING TROUBLESHOOTING CAN CAUSE SERIOUS PROBLEMS WITH THE POWER BURNER’S OPERATING SEQUENCE AND IGNITION SAFETY. IF YOU DO NOT HAVE THE PROPER TEST EQUIPMENT, I.E. A VOLT-OHM METER AND A MICRO-AMMETER DO NOT ATTEMPT TO TROUBLESHOOT OR REPAIR STATE EQUIPMENT.

ALTERING THE IGNITION MODULE AND/OR CONTROL BOX WIRING INANY WAY COULD RESULT IN INTERNAL DAMAGE TO THE MODULE CIRCUITS, POSSIBLY ALTERING THE IGNITION SEQUENCE ALLOWING GAS VALVES TO OPEN BEFORE THE HOT SURFACE IGNITER IS UP TO IGNITION TEMPERATURE.

NOTE: ANY BYPASS OR ALTERATION OF THE UNITS SAFETIES WILL RESULT IN VOIDING THE APPLIANCE WARRANTY.

Before performing any troubleshooting familiarize yourself with the particular appliance. State power burners are supplied with Honeywell® ignition control systems and Robertshaw® gas control valves, see Figures 10 and 11.

Refer to the SEQUENCE OF OPERATION and burner exploded view, see Figure 12 and the wiring diagram located on page

30®Honeywell is a registered trademark of Honeywell International Inc.