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MODELS GPG/GPV-540A, 650A AND 740A
COMMERCIAL GAS, GLASS-LINED, TANK-TYPE LOW NOx
WATER HEATER
• INSTALLATION • OPERATION • MAINTENANCE • LIMITED WARRANTY
CAUTION
TEXT IN BLACK BOLD TYPE OR UNDERLINED
CONTAINS INFORMATION RELATIVE TO YOUR
SAFETY. PLEASE READ THOROUGHLY BEFORE
INSTALLING AND USING THIS APPLIANCE.
ASHLAND CITY, TN
www.statewaterheaters.com
PLACE THESE INSTRUCTIONS ADJACENT TO HEATER AND
NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.
PRINTED IN U.S.A. 1004
PART NO. 195047-000
1
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Table of Contents
Troubleshooting
Related Manuals for State Water Heaters GPG-540A
Summary of Contents for State Water Heaters GPG-540A
- Page 1 MODELS GPG/GPV-540A, 650A AND 740A COMMERCIAL GAS, GLASS-LINED, TANK-TYPE LOW NOx WATER HEATER • INSTALLATION • OPERATION • MAINTENANCE • LIMITED WARRANTY CAUTION TEXT IN BLACK BOLD TYPE OR UNDERLINED CONTAINS INFORMATION RELATIVE TO YOUR SAFETY. PLEASE READ THOROUGHLY BEFORE INSTALLING AND USING THIS APPLIANCE.
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Page 2: Rough-In-Dimensions
ROUGH-IN DIMENSIONS STANDARD BAROMETRIC DRAFT CONTROL GPG MODELS ALL DIMENSIONS IN INCHES (MILLIMETERS) Models GPG/GPV 80 3/4 540A 2,051 1,854 GPG/GPV 80 3/4 650A 2,051 1,854 GPG/GPV 80 3/4 740A 2,051 1,854 *Minimum gas supply pipe is 1 1/4”, reference Table 7 for gas supply pipe size. Storage Capacity Models... -
Page 3: Table Of Contents
In addition to these instructions, the equipment shall be installed in accordance with those installation regulations in accordance with those installation regulations in force in the local area where the installation is to be made. These shall be carefully followed in all cases. -
Page 4: Improper Combustion
and sodium chloride (water softener salt), waxes, and process chemicals are typical compounds which are potentially corrosive. Do not store products of this sort near the heater. Also, air which is brought in contact with the heater should no contain any of these chemicals. -
Page 5: Dishwashing Machine Requirement
Continued manual resetting of high limit control, preceded by higher than usual water temperature is evidence of high limit switch operation. The following are possible reasons for high limit switch operation. • A malfunction in the thermostatic controls would allow the gas valve to remain open causing water temperature to exceed the thermostat setting. -
Page 6: Hard Water
Units, which are to be installed on combustible flooring, must be supported by a full layer of hollow concrete blocks, from 8” (203.2 mm) to 12” (304.8 mm) thick and extending 12” (304.8 mm) minimum beyond the heater in all directions. The concrete blocks must provide an unbroken concrete surface under the heater with the hollows running continuously and horizontally. -
Page 7: Venting
Refer to Table 1 for the vent pipe size required for installation to the barometric draft control assembly outlet. TABLE 1. Model GPG-540A 9” (228.6 mm) GPG-650A 9” (228.6 mm) GPG-740A 9” (228.6 mm) Single-wall or type B venting may be used with these heaters in vertical vent installations. - Page 8 Refer to Table 2 for limitations of venting system design for horizontal venting. TABLE 2 Flue Outlet Dia. (Inches/mm) Flue Reducer Dimensions -Supplied (Inches/mm) Minimum Outlet Vent Dia. (Inches/mm) Maximum Number 90° Of Elbows 45° Maximum Total Vent System Length, Equiv. Feet/Meters When calculating the equivalent length of a venting system each 90°...
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Page 9: Direct Venting - For Gpv Models
DIRECT VENTING - FOR GPV MODELS All exhaust vent terminal, flue reducer, and intake vent terminal are supplied with any unit intended for direct venting. These parts must be installed without alteration. This heater is category III appliance when used in a direct vent application. - Page 10 1. Shall be located not less than 12” (304.8 mm) above grade. 2. Shall be located not less than 3 (.9144 m) feet horizontally from and not less than 3 feet (.9144 m) below an exhaust vent terminal. 3. Shall not be located directly above an exhaust terminal. 4.
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Page 11: Gas Piping
Attach a properly sized length of Selkirk Metalbestos model PS or model G venting to the exhaust vent adapter using the inner vee bands, see Figures 7 and 7B on page 10. Fill the grooves in both inner vee bands with high-temp silicone sealant, Dow Corning 736 or equivalent. -
Page 12: Gas Meter Size
TABLE 9A MAXIMUM CAPACITY OF PIPE IN CUBIC FEET OF GAS PER HOUR (Based upon a Pressure Drop of 0.5 inch Water Column and 0.5 Specific Gravity Gas and max. gas press. of .5 psig) LENGTH Nominal Iron Pipe Sizes, Millimeters METERS 1/2"... -
Page 13: Water Line Connections
ROBERTSHAW ® 7000 DERHC GAS CONTROL VALVE FIGURE 10. WATER LINE CONNECTIONS Following are detailed installation diagrams for typical methods of application for the water heaters. The water heater may be installed by itself, or with a separate storage tank, on both single and two-temperature systems. When used with a separate storage tank, the circulation may be either by gravity or by means of a circulating pump. -
Page 14: Installation Diagrams
INSTALLATION DIAGRAMS ONE TEMPERATURE - ONE HEATER VERTICAL STORAGE TANK FORCED CIRCULATION WITH OR WITHOUT BUILDING RECIRCULATION NOTE: WHEN USING A State T-140, 200, 350 OR 400 STORAGE TANK, USE LOWER 3/4” OPENING FOR TANK TEMP. CONTROL ONE TEMPERATURE - ONE HEATER HORIZONTAL STORAGE TANK FORCED CIRCULATION WITH OR WITHOUT BUILDING RECIRCULATION *PIPE TO OPEN DRAIN INSTALL IN ACCORDANCE WITH LOCAL CODES... - Page 15 TWO TEMPERATURE - ONE HEATER HIGH TEMPERATURE WITH OR WITHOUT BUILDING RECIRCULATION WIRING DIAGRAM FOR TEMPERED WATER LOOP (IF USED) CIRCULATING PUMP WIRING DIAGRAM TWO TEMPERATURE - TWO HEATERS HIGH TEMPERATURE WITH OR WITHOUT BUILDING RECIRCULATION *PIPE RELIEF VALVE TO OPEN DRAIN NOTE: IF TEMPERED WATER...
- Page 16 TWO TEMPERATURE - THREE HEATERS (TWO PRE-HEATERS/ONE BOOSTER) WITH OR WITHOUT BUILDING RECIRCULATION CAUTION: IF BUILDING COLD WATER SUPPLY HAS A BACKFLOW PREVENTER, CHECK VALVE OR WATER METER WITH CHECK VALVE, PROVISIONS FOR THERMAL EXPANSION OF WATER IN THE HOT WATER SYSTEM MUST BE PROVIDED.
- Page 17 TWO TEMPERATURE - ONE HEATER HIGH TEMPERATURE DANGER TEMPERATURE SETTING SHOULD NOT EXCEED SAFE TEMPERATURE AT FIXTURES. SEE WATER TEMPERATURE CONTROL WARNING ON PAGE 23. IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT, ADD AN ANTI-SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES.
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Page 18: Manifold Kits
MANIFOLD KITS TWO UNIT MANIFOLD KIT PART NO. 195702 Precision cut type “L” all copper State manifold kits assure water flow balance of all units. Without this balance, the full water heating and storage potential of the system cannot be achieved. Plus, the units with the higher water flow may have a shortened life. -
Page 19: Heater Wiring
HEATER WIRING IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED, IT MUST BE REPLACED WITH 105°C WIRE OR ITS EQUIVALENT, EXCEPT IN THE BURNER HOUSING USE 200°C WIRE. The power burner is wired to the heater as shown in Figure 11 for GPG models and Figure 12 for GPV models. -
Page 20: Wiring Diagram
FIGURE 11. - Page 21 FIGURE 12.
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Page 22: Lighting And Operating Label
FOR YOUR SAFETY READ BEFORE LIGHTING WARNING: explosion may result causing property damage, personal injury or loss of life. BEFORE OPERATING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES. A. This appliance is equipped with an ignition device which automatically lights the burner. -
Page 23: Sequence Of Operation
SEQUENCE OF OPERATION – Power on. – Heater in standby mode. – Thermostat calls for heat. – Blower motor starts. – Blower operation closes the normally open blower prover/ blocked outlet safety pressure switch. – On proof of airflow, Honeywell S8680J flame control module energized. -
Page 24: Adjustment Procedure For Fire-Rate, Low Nox And High Elevation (Fine-Tune)
1. Check gas line pressure with a manometer. Set initial gas line pressure at 9-10” w.c. before turning the heater “ON”. Read gas line pressure and gas manifold pressure when the heater main gas is “ON”. Adjust gas line regulator setting if the gas line pressure drops below 8”... - Page 25 PREMIX LOW NOx BURNER - EXPLODED VIEW FOR GPG MODELS FIGURE 13.
- Page 26 PREMIX LOW NOx BURNER - EXPLODED VIEW FOR GPV MODELS FIGURE 14.
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Page 27: General Information
GENERAL INFORMATION POWER BURNER The initial start-up procedure of the gas power burner is provided on page 18 thru 21. Refer to Figure 12, burner exploded view for burner components location. The sequence of operation of the power burner is provided on page 15. -
Page 28: Draining
DRAINING The heater must be drained if it is to be shut down and exposed to freezing temperatures. Maintenance and service procedures may also require draining the heater. 1. Turn off the heater electrical disconnect switch. 2. Close the cold water inlet valve to heater. 3. -
Page 29: Circulating Pump
ABOVE ALL, DO NOT PLUG THE TEMPERATURE AND PRESSURE RELIEF VALVE. THIS IS NOT A SOLUTION AND CAN CREATE A HAZARDOUS SITUATION. CIRCULATING PUMP The water heating system may include a circulating pump. Where used, it should be lubricated as directed by the circulator manufacturer. -
Page 30: Troubleshooting
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. •... - Page 31 and the troubleshooting section of burner manual before continuing. Make sure the appliance is connected to a 120 Vac power supply, burner switch is “ON” and manual gas valve is in the “ON” position, and all electrical connections are secure before continuing to troubleshoot this appliance.
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Page 32: Troubleshooting
5. As soon as the pilot gas valve is energized, check for the burner pilot flame through the burner peek-hole. If the pilot flame is established inside the burner, then proceed to Step 6. • Turn the burner switch to “OFF” position for at least one minute to reset the heater. -
Page 33: Warranty
State Industries, Inc., the warrantor, extends the following LIMITED WARRANTY to the owner of this water heater. 1. THE TANK If the glass-lined tank in this water heater shall prove upon examination by the warrantor to have leaked due to the natural corrosion from potable water therein, during the first THREE years after installation, the warrantor will supply a complete new State water heater of equivalent size and current model. -
Page 34: Parts List
COMMERCIAL TANK TYPE WATER HEATER REPLACEMENT PARTS LIST MODELS GPG/GPV-540A THRU 740A SERIES 104 GPV VENT KIT CLEANOUT ASSEMBLY RELIEF BAROMETRIC VALVE DRAFT CONTROL (Part numbers are listed on page 35) STATE WATER HEATERS 500 Lindahl Parkway, Ashland City, TN 37015 Phone: 1-800-821-2017 •... - Page 35 ... 11C ... Screw - Thread Rolling ... 69852-1 ... 69852-1 ... 69852-1 *Items not illustrated. # Quantities, if more than one, shown in parenthesis next to part number. Part numbers underlined are recommended stock items for emergency replacement. PART LIST FOR PAGE 34 GPG-540A GPV-540A GPG-650A GPG-740A GPV-650A...
- Page 36 GPG BURNER ASSEMBLY (Part numbers are listed on page 37)
- Page 37 51 ... Pilot Tubing (3) ... 6207-54 ... 6207-54 ... 6207-54 52 ... Rocker Switch ... 6207-46 ... 6207-46 ... 6207-46 53 ... O Ring Seal ... 6207-55 ... 6207-55 ... 6207-55 54 ... Plastic Cap, SC-1 1” Pipe ... 6207-56 ... 6207-56 ... 6207-56 GPG-540A GPG-650A GPG-740A...
- Page 38 GPV BURNER ASSEMBLY (Part numbers are listed on page 39)
- Page 39 PART LIST FOR BURNER (see drawing on page 38) Item Description 1 ... Ignition Control ... 6207 ... 6207 ... 6207 2 ... Motor - 1/4 HP 3450 RPM ... 6207-1 ... 6207-1 ... 6207-1 3 ... Valve 24/60 ... 6207-2 ... 6207-2 ... 6207-2 4 ...
- Page 40 500 Lindahl Parkway, Ashland City, TN 37015 Phone: 800-821-2017 Fax: 800-644-9306 www.statewaterheaters.com...