State Water Heaters GPG 81-140 Instruction Manual
State Water Heaters GPG 81-140 Instruction Manual

State Water Heaters GPG 81-140 Instruction Manual

Series 104/105 commercial gas water heaters
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500 Tennessee Waltz Parkway
Ashland City, TN 37015
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 0313
commercial gas water heaters

instruction manual

models gpg 81-140 thru 81-370
installation - operation - serVice
- maintenance - limited warranty
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.
series 104/105
195091-002

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Summary of Contents for State Water Heaters GPG 81-140

  • Page 1: Instruction Manual

    81-140 thru 81-370 series 104/105 installation - operation - serVice - maintenance - limited warranty 500 Tennessee Waltz Parkway Ashland City, TN 37015 Low Lead Content WARNING: If the information in these...
  • Page 2: Table Of Contents

    table of contents SAFe INSTAllATION, uSe AND SerVICe ........3 Air From Other Indoor Spaces ............18 APPrOVAlS ..................3 Vent Connection ................19 GeNerAl SAFeTy INFOrmATION ..........4-5 WATer HeATer INSTAllATION ..........19-22 Precautions ..................5 Water line Connections ..............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 Do not store or use gasoline or other flammable vapors and For continued protection against liquids in the vicinity of this or any other appliance. risk of fire: 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

    5. table 1 . models gpg 81-140 thru 81-370 approX. ship. wt. models (lbs.) asme std. 65" 26 3/4" 6" 21 3/8" 27 3/4" 38" 85 1/4" 1 1/2" 1 1/2" GPG 81-140 74 3/4"...
  • Page 9 120V, 60hz, 10 GPG 81-140 140,000 GPG 81-199 199,000 GPG 81-270 270,000 GPG 81-370 370,000 models with letter “A” following the model number have the optional ASme tank construction **The GPG 81-370 is available in natural gas only.
  • Page 10: Locating The Water Heater

    (leftside) (back) (ceiling) The heater shall be located or protected so it is not subject to physical damage by a moving vehicle. GPG 81-140 6" (15.24 cm) 6" (15.24 cm) 6" (15.24 cm) 21" (53.34 cm) GPG 81-199 Flammable items, pressurized containers or any other potential 6"...
  • Page 11: Insulation Blanket

    is to reduce the standby heat loss encountered with storage tank heaters. The water heaters covered by this manual meet or exceed the energy Policy Act standards with respect to insulation and standby heat loss requirements, making an insulation blanket unnecessary. Should you choose to apply an insulation blanket to this heater, you should follow these instructions.
  • Page 12: High Altitude Installations

    CIRCULATING PUMP WIRING DIAGRAM CIRCULATING PUMP WIRING DIAGRAM DISHWASHER LOOP WITH TOGGLE SWITCH STORAGE TANK OR BUILDING RECIRCULATION FIELD SUPPLIED TEMPERATURE CONTROL DISHWASHER FIELD SUPPLIED TEMPERATURE Breathing Hazard - Carbon Monoxide Gas INSTALLED IN THE STORAGE TANK TOGGLE CONTROL INSTALLED IN THE OR CIRCULATING LOOP RETURN LINE SWITCH CIRCULATING LOOP RETURN LINE...
  • Page 13: Installation Requirements

    installation reQuirements 4. When installing multiple water heaters in the same gas supply gas supply systems 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 agency to have a OUTLET thermal expansion tank installed. See Water line Connections on page 19 and the Water Piping 12”...
  • Page 15: Temperature-Pressure Relief Valve

    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: Fresh Air Opening For Confined Spaces

    fresh air openings for confined spaces Alternatively a single permanent opening, commencing within 12 inches (300 mm) of the top of the enclosure, The following instructions shall be used to calculate the size, shall be provided. See Figure 12. The water heater shall number and placement of openings providing fresh air for have clearances of at least 1 inch (25 mm) from the sides combustion, ventilation and dilution in confined spaces.
  • Page 18: Outdoor Air Through Two Vertical Ducts

    outdoor air through two Vertical ducts When ducts are used, they shall be of the same cross sectional area as the free area of the openings to which they connect. The illustrations shown in this section of the manual are a The minimum dimension of rectangular air ducts shall be not less reference for the openings that provide fresh air into confined than 3"...
  • Page 19: Vent Connection

    In venting systems where a continuous or intermittent GPG 81-140 6” back (positive) draft is found to exist, the cause must be determined and corrected. In some cases, a special GPG 81-199 6”...
  • Page 20: Installation Diagrams - Top Inlet/Outlet Usage

    This water heater is provided with a properly rated/sized and tube inlet installation certified combination temperature - pressure (T&P) relief valve by the manufacturer. See Temperature-Pressure relief Valve on pages 14-15 for information on replacement and other requirements. CAUTION Water Damage Hazard figure 17.
  • Page 21: Heater Wiring

    heater wiring All electrical work must be installed in accordance with the current edition of the National electrical Code ANSI/NFPA No. 70 or Canadian electrical Code CSA C22.1 and must conform to all local code authority having jurisdiction. AN eleCTrICAl GrOuND IS requIreD TO reDuCe rISk OF eleCTrICAl SHOCk Or POSSIBle eleCTrOCuTION.
  • Page 22: Gas Piping

    gas piping Apply joint compounds (pipe dope) sparingly and only to the male threads of pipe joints. Do not apply compounds to the first two threads. Contact your local gas service company to ensure that adequate use compounds resistant to the action of liquefied petroleum gases. gas service is available and to review applicable installation codes gas meter siZe –...
  • Page 23: Startup And Operation

    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 24: Sequence Of Operation Flow Chart

    seQuence of operation flow chart Description of this flow chart can be found in the “SequeNCe OF OPerATION” section found on page 25. START THERMOSTAT CALLS FOR HEAT. POWER INTERUPTION. SYSTEM SHUTS OFF. RESTARTS SAFE WHEN POWER IS RESTORED. START SAFE START CHECK CHECK...
  • Page 25: Lighting & Operation Label

    lighting & operation label figure 21. label for natural and lp gas models...
  • Page 26: Adjustments

    (for lp gas (btuh) cu. ft. gas in sec.) in sec.) checking the input 1050 GPG 81-140 140000 27. 2 64.7 2500 For installation locations with elevations above 2000 feet, refer to HIGH AlTITuDe INSTAllATIONS section of this manual 1050...
  • Page 27: Setting Burner Operation

    81-140 gpg 81-199 gpg 81-270 gpg 81-370 shutter adjustments per Table 9. Combustion results from max. Gas line Press.(W.C.) Nat. Gas - 10.5” W.C./Prop. Gas -13.0” Table 9 are for natural gas models.
  • Page 28: 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 29: 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 30: Deliming Solvents

    Prepare the Water Heater To delime the water heater using the Flo-Jug method, first prepare the heater for deliming. Explosion Hazard Flammable hydrogen gases may be present. Keep all ignition sources away from faucet when turning on hot water. Do not smoke or have open flame or sparks in vicinity of heater. Do not mix uN•lIme with other chemicals.
  • Page 31: Power Burner

    7. lower container, you may have to place the container on its empty carton to prevent the uN•lIme from flowing back into 1. Add a few drops of no. 20 non-detergent oil (GPG 81-140 Thru 81-370) into the oil tubes once every three months.
  • Page 32: Gas Control Valve

    gas control ValVe Figure 30 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 30. serVice electrical serVicing The installer may be able to observe and correct certain problems which may arise when the unit is put into operation.
  • Page 33: Troubleshooting Checklist

    troubleshooting checklist remedy complaint cause user Qualified serVice agency Set thermostat dial to a higher Thermostat set too low. temperature. Check continuity and resistance Water not hot enough. upper and/or lower temperature (Ohms) of upper and lower Call qualified service agency. probe out of calibration.
  • Page 34: For Your Information

    for your information A sulfate reducing bacteria which has accumulated start up conditions within the water heater (this harmless bacteria is nontoxic to humans). smoke/odor An excess of active hydrogen in the tank. This is caused It is not uncommon to experience a small amount of smoke and by the corrosion protective action of the anode rod.
  • Page 35: Water Piping Diagrams

    water piping diagrams...
  • Page 45 STORAGE TANK...
  • Page 48 STORAGE TANK...
  • Page 50: Manifold Kits

    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 51: Replacement Parts List

    (decimal) part no. (decimal) GPG 81-140 HSG-200 62459-001 0.24 62459-001 0.209 GPG 81-199 HSG-200 62459-001 0.38 62459-001 0.257 GPG 81-270 HSG-400 62459-002 0.368 62459-002 0.302...
  • Page 52 81-140 gpg 81-199 gpg 81-270 gpg 81-370 1 ..Anode ............9003892005(2) ..9003892005(2) ..9003892005(2) ..9003892005(2) 2 ..Baffle, Flue ..........9005293205(7) ..9005293205(7) ..9005293205(7) ..9005293205(7) 3 ..Barometric Draft Control w Tee Assy..9500007199 ... 9500007199 ...9500007200 ....9500007200 cleanout assembly: 4 ..
  • Page 53: Notes

    notes...
  • Page 54: Notes

    notes...
  • Page 55: Warranty

    Factory Start-up is required for activating warranty and assuring maximum operating performance. Contact your local sales representatives or Authorized Start- up Agent to arrange a Free Certified Start-up. State Water Heaters , the warrantor, extends the following lImITeD WArrANTy to the owner of this water heater.
  • Page 56 500 Tennessee Waltz Parkway, Ashland City, TN 37015 Technical Support: 800-365-8170 • Parts: 800-821-2017 www.statewaterheaters.com Copyright © 2013 State Industries, Inc., All rights reserved.

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