State Water Heaters 104 Series Instruction Manual
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State Water Heaters 104 Series Instruction Manual

State Water Heaters 104 Series Instruction Manual

Commercial gas water heaters
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500 Tennessee Waltz Parkway
Ashland City, TN 37015
www.statewaterheaters.com
Low Lead Content
WARNING: If the information in these
instructions is not followed exactly, a fire
or explosion may result causing property
damage, personal injury or death.
Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS:
•
Do not try to light any appliance.
•
Do not touch any electrical switch; do
not use any phone in your building.
•
Immediately call your gas supplier
from a neighbor's phone. Follow the
gas supplier's instructions.
•
If you cannot reach your gas supplier,
call the fire department.
Installation and service must be
performed by a qualified installer,
service agency or the gas supplier.
Thank you for buying this energy efficient water heater.
We appreciate your confidence in our products.
place these instructions adjacent to heater and notify owner to keep for future reference.
PRINTED 0714
commercial gas water heaters
instruction manual
models gpg/gpV-540a, 650a and 740a
installation - operation - serVice
- maintenance - limited warranty
series 104/105
Read and understand this instruction
manual and the safety messages
herein before installing, operating or
servicing this water heater.
Failure to follow these instructions and
safety messages could result in death
or serious injury.
This manual must remain with the
water heater.
195047-003

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Summary of Contents for State Water Heaters 104 Series

  • Page 1 instruction manual commercial gas water heaters models gpg/gpV-540a, 650a and 740a series 104/105 installation - operation - serVice - maintenance - limited warranty 500 Tennessee Waltz Parkway Ashland City, TN 37015 www.statewaterheaters.com Low Lead Content WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death.

  • Page 2: Table Of Contents

    table of contents SAfE INSTALLATION, USE AND SErVICE ........3 Barometric Draft Control Assembly ..........18 aPPRovals ..................3 Vent Connection ................18 GENErAL SAfETy INfOrMATION ..........4-5 Horizontal (Side-Wall) Venting for GPV Models ......18-19 Precautions ..................5 Direct Venting for GPV Models ............19 Grounding Instructions ..............

  • Page 3: Safe Installation, Use And Service

    safe installation, use and serVice The proper installation, use and servicing of this water heater is extremely important to your safety and the safety of others. Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard.

  • Page 4: General Safety Information

    general safety information Fire or Explosion Hazard Fire Hazard For continued protection against Do not store or use gasoline or other flammable vapors and risk of fire: liquids in the vicinity of this or any other appliance. • Do not install water heater on Avoid all ignition sources if you smell gas.

  • Page 5: Precautions

    general safety information Read and understand this instruction Explosion Hazard manual and the safety messages herein before installing, operating or Overheated water can cause servicing this water heater. water tank explosion. Failure to follow these instructions and Properly sized temperature and safety messages could result in death pressure relief valve must be or serious injury.

  • Page 6: Introduction

    introduction Thank you for purchasing this water heater. Properly installed Warranty on this product is limited and could be void in the event the unit is not installed per the instructions in this manual and maintained, it should give you years of trouble free service. and/or not started up by an authorized factory trained service/ abbreViations used start-up provider.

  • Page 7: Features And Components

    features and components high limit switch barometric draft control The dual bulb controller (fig. 1) contains the high limit (energy cutoff) The heater is equipped with a double acting barometric draft sensor. The high limit switch interrupts main burner gas flow should control.

  • Page 8: Installation Considerations

    installation considerations rough in dimensions standard barometric draft control horiZontal & direct Venting gpg models gpV models m a X i m u m t o ta l 7 5 eQuiValent feet intake and eXhaust allowed. figure 5. table 1 . models gpg/gpV-540a through gpg/gpV-740a approx.
  • Page 9 installation considerations table 2. heater performance data gpg/gpV models storage input rating recovery rating recovery rating current draw capacity btu/hr. 120V models u.s. gals. (litres) nat. 100°f rise* 140°f rise* gohz 1 phase GPG/GPV-540A 85 (261) 540,000 523.6 6.0 Amps GPG/GPV-650A 85 (261) 650,000...

  • Page 10: Locating The Water Heater

    installation considerations locating the water heater flammable items, pressurized containers or any other potential fire hazardous articles must never be placed on or adjacent to the heater. Open containers or flammable material should not be CAUTION stored or used in the same room with the heater. Property Damage Hazard The heater must not be located in an area where it will be subject to freezing.

  • Page 11: Insulation Blanket

    • do not cover the instruction manual. Keep it on the side of the water heater or nearby for future reference. • do obtain new warning and instruction labels from the manufacturer for placement on the blanket directly over the existing labels.

  • Page 12: High Altitude Installations

    high altitude installations your State water heater has been designed to operate at altitudes below 2000 ft. (609.6 m). for appliance installation locations with elevations above 2000 ft. (609.6 m), special considerations need to be taken. Adjustments for high altitude can only be made by an State authorized GPG/GPV Start-up Fire and Explosion Hazard Agent.

  • Page 13: Installation Requirements

    installation reQuirements gas supply systems 4. When installing multiple water heaters in the same gas supply system it is recommended that individual positive lock-up gas Low pressure building gas supply systems are defined as those pressure regulators be installed at each unit. systems that cannot under any circumstances exceed 14”...

  • Page 14: Dishwashing Machines

    A properly sized thermal expansion tank must be installed on all closed systems to control the harmful effects of thermal HOT WATER expansion. Contact a local plumbing service technician to have a OUTLET thermal expansion tank installed. See Water Line Connections on page 24 and the Water Piping 12”...

  • Page 15: Contaminated Air

    contaminated air No valve or other obstruction is to be placed between the Temperature-Pressure relief Valve and the tank. Do not connect discharge piping directly to the drain unless a 6” (15.2 cm) air gap is provided. To prevent bodily injury, hazard to life, or property damage, the relief valve must be allowed to discharge Breathing Hazard - Carbon Monoxide Gas water in adequate quantities should circumstances demand.

  • Page 16: Unconfined Space

    unconfined space direct Vent appliances Appliances installed in a Direct Vent configuration that derive all An Unconfined Space is one whose volume IS NOT LESS THAN air for combustion from the outdoor atmosphere through sealed 50 cubic feet per 1,000 Btu/hr (4.8 cubic meters per kW) of the intake air piping are not factored in the total appliance input Btu/ total input rating of all appliances installed in the space.

  • Page 17: Outdoor Air Through Two Horizontal Ducts

    vertical or horizontal duct to the outdoors or spaces that freely The confined space shall be provided with two permanent vertical communicate with the outdoors and shall have a minimum free ducts, one commencing within 12 inches (300 mm) of the top and area of the following: one commencing within 12 inches (300 mm) of the bottom of the 1.

  • Page 18: Barometric Draft Control Assembly

    • Where a separate vent connection is not available and the Vent connectors making horizontal runs must have a minimum vent pipe from the heater must be connected to a common upward slope toward the chimney or vent of 1/4 inch per foot. Vent connector length should be kept as short as possible.

  • Page 19: Sidewall Termination Installation

    sidewall termination installation 6. Install the flue reducer included with the exhaust hood between the vent system and the heater. 1. If installing only vent (exhaust) piping in a Power Vent 7. Seal all vent connections and venting with sealants supplied configuration through a sidewall;...

  • Page 20: Termination Clearances Sidewall Power Vent

    termination clearances sidewall power Vent POWER VENT (using room air for combustion) EXTERIOR CLEARANCES FOR SIDEWALL VENT TERMINATION F IX E D C L O S E D O P E R A B L F IX E D C L O S E D O P E R A B L VENT TERMINAL AIR SUPPLY INLET...

  • Page 21: Termination Clearances Sidewall Direct Vent

    termination clearances sidewall direct Vent DIRECT VENT (using outdoor air for combustion) EXTERIOR CLEARANCES FOR SIDEWALL VENT TERMINATION F IX E D C L O S E D O P E R A B L F IX E D C L O S E D O P E R A B L VENT TERMINAL AIR SUPPLY INLET...
  • Page 22 direct Vent system installation 11. Use an expansion joint between any two fixed points in the exhaust venting system wherever the expansion may exceed Plan the vent system backwards from the vent hood to the heater. 1/4”. Selkirk Metalbestos model PS and model G venting 1.
  • Page 23 figure 19b. figure 19.

  • Page 24: Water Heater Installation

    water heater installation water line connections t&p ValVe discharge pipe The water piping installation must conform to these instructions and to all local code authority having jurisdiction. Good practice requires that all heavy piping be supported. Explosion Hazard read and observe all requirements in the following sections before installation of the water piping begins: Temperature-Pressure Relief Valve must comply with ANSI Z21.22-...

  • Page 25: Installation Diagrams - Top Inlet/Outlet Usage

    installation diagrams - top inlet/outlet usage heater wiring Use of the top inlet water connection requires an inlet dip tube All electrical work must be installed in accordance with the (refer to figure 20). The tube is supplied in the heater. follow current edition of the National Electrical Code ANSI/NfPA No.

  • Page 26: Gas Piping

    figure 22. gas piping Schedule 40 Steel or Wrought Iron Pipe is the preferred material for the gas line of this water heater. It is imperative to follow the Contact your local gas service company to ensure that adequate sizing recommendations in the latest version of the National fuel gas service is available and to review applicable installation codes Gas Code if Corrugated Stainless Steel Tubing (CSST) is used as for your area.

  • Page 27: Gas Line Leak Testing

    emergency malfunction of the supply system, the gas valve must be two threads. Use compounds resistant to the action of liquefied petroleum gases. checked for safe operation. Make sure that the outside vents on the supply regulators and the safety vent valves are protected against gas meter siZe –...

  • Page 28: Prior To Start Up

    start-up and operation • Attach a gas pressure gauge or manometer to upstream side of main gas cock and a gas pressure gauge or manometer to the manifold pressure tapping. Fire or Explosion Hazard • Check voltage at disconnect switch to make certain that it matches that shown on the burner label.
  • Page 29 If gas line pressure fluctuates around the setpoint too quick 17. Thermostat is satisfied, switch opens. (less than a second) burner may still run with excessive gas 18. Power is interrupted to the flame control module and blower valve ON/Off cycle you must turn off the unit immediately, motor.

  • Page 30: Lighting & Operation Label

    lighting & operation label for your safety read before lighting warning: If you do not follow these instructions exactly, a fire or 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. • If you cannot reach your gas supplier, call the fire A.

  • Page 31: Adjustments

    adjustments important note: final gas and air settings should be based on flue gas CO or o reading (see Table 3). Increase burner A minimum dynamic gas supply pressure of 8” w.c. for natural manifold pressure will increase fire rate and flue gas CO reading.
  • Page 32 premiX low nox burner - eXploded View for gpg models figure 25. for all parts on this burner contact: Wayne Combustion Systems, 801 Glasgow Ave., fort Wayne, IN 46803...
  • Page 33 premiX low nox burner - eXploded View for gpV models figure 26. for all parts on this burner contact: Wayne Combustion Systems, 801 Glasgow Ave., fort Wayne, IN 46803...

  • Page 34: Maintenance

    maintenance Venting system and barometric draft control heater where the thermostat senses the drop in water temperature and activates main burner operation of the water heater. The heater is equipped with a double acting barometric draft If the storage tank temperature control is out of calibration, replace control.

  • Page 35: Anode Rod Inspection

    It is recommended that the water heater storage tank be drained and flushed every 6 months to reduce sediment buildup. The water heater should be drained if being shut down during freezing temperatures. See features And Components in this manual for Explosion Hazard the location of the water heater components described below.

  • Page 36: Deliming Solvents

    Prepare the Water Heater 180°F To delime the water heater using the flo-Jug method, first For 10 Grain Hardness Lime Deposited vs. Temperature prepare the heater for deliming. and Water Use Data From Purdue Bulletin 74 170°F 160°F Explosion Hazard Flammable hydrogen gases may be present.

  • Page 37: Power Burner

    While the water is being run through the tank, insert a Normally, lime removal will be completed within one hour. stiff wire, copper tube flattened at one end or an opened Severe build-up of lime may take longer than an hour to complete wire coat hanger through the cleanout opening and descaling.

  • Page 38: Gas Control Valve

    gas control ValVe figure 32 shows the combination gas control valves used on these heaters. If gas control valve becomes defective, repairs should not be attempted. A new valve should be installed in place of defective one. figure 32. serVice The installer may be able to observe and correct certain problems electrical serVicing which may arise when the unit is put into operation.
  • Page 39 • Check for the continuity between the flame rod and • If 24V is detected for a period of 15 seconds, check for the changes sensor connection at Honeywell flame control module by of gas supply line pressure when the pilot gas valve is energized. the ohm meter.

  • Page 40: For Your Information

    8. Verify the air switch setting is not too high. gas fails to shut off 9. Check the venting system for the correct sizing, excessive or Check for defective gas valve or thermostat. If operation is insufficient draft, and proper operation of the barometric draft incorrect, replace.

  • Page 41: Water Piping Diagrams

    water piping diagrams...
  • Page 51 STORAGE TANK...
  • Page 54 STORAGE TANK...

  • Page 56: Prior To Start-Up

    manifold kits Dimensions shown are for minimum space occupied by the water heaters assemblies. Space for the barometric draft control assemblies, combustion clearances and servicing must be added. prior to start up important factory Start-Up is required for activating warranty and assuring maximum operating performance.

  • Page 57: Replacement 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 state water heaters 125 southeast parkway, franklin, tn 37068 1-800-821-2017 www.statewaterheaters.com...
  • Page 58 item description gpg-540a gpg-650a gpg-740a 1..Anode, Plug ..............9003892005(4) ....9003892005(4) ..... 9003892005(4) 2..Baffle, flue ...............9006832005(24) ..9006832005(24) ... 9006832005(24) 3..Valve, relief ................9006187205 ....9006187205 ....9006187205 4..Thermostat W.E.C.O............9004529005 ....9004529005 ....9004529005 5..Cover, front ................181260 ......181260 ......181260 6..

  • Page 59: Warranty

    Serial: ___________________ Model: ___________________ U.S. Customers: state water heaters 500 tennessee waltz parkway ashland city, tennessee 37015 800-365-0024 www.statewaterheaters.com...
  • Page 60 500 Tennessee Waltz Parkway, Ashland City, TN 37015 Technical Support: 800-365-8170 • Parts: 800-821-2017 www.statewaterheaters.com Copyright © 2014 State Industries, Inc., All rights reserved.

This manual is also suitable for:

105 seriesGpg-540aGpg-650aGpg-740aGpv-540aGpv-650a ... Show all

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