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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.
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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Table of Contents
Related Manuals for State Water Heaters GPG/GPV-540A
Summary of Contents for State Water Heaters GPG/GPV-540A
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Page 1: Instruction Manual
Instruction Manual COMMERCIAL GAS WATER HEATERS MODELS GPG/GPV-540A, 650A AND 740A SERIES 104/105 INSTALLATION - OPERATION - SERVICE - MAINTENANCE - LIMITED WARRANTY 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 APPROVALS 18-19 WATER HEATER INSTALLATION Preparing for the Installation Heater Wiring 25-26 26-27 Purging 28-29 8-12 Lighting & Operation Label Insulation Blanket 13-16 34-35 13-14 35-36 36-37 14-15 38-39 16-19 16-17 41-55 57-58 Venting 17-18... -
Page 3: Approvals
SAFE INSTALLATION, USE AND SERVICE This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. DANGER indicates an imminently hazardous situation which, if not avoided, DANGER will result in injury or death. - Page 4 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 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.
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Page 6: Preparing For The Installation
INTRODUCTION ABBREVIATIONS USED PREPARING FOR THE INSTALLATION QUALIFICATIONS QUALIFIED INSTALLER OR SERVICE AGENCY ANSI Z223.1 2006 Sec. 3.3.83: START UP REQUIREMENTS... - Page 7 FEATURES AND COMPONENTS HIGH LIMIT SWITCH BAROMETRIC DRAFT CONTROL BAROMETRIC DRAFT CONTROL FIGURE 3. COMBUSTION CHAMBER OBSERVATION PORT DIGITAL THERMOSTAT FIGURE 1. ELECTRONIC IGNITION CONTROL FIGURE 4. UNCRATING MPLS., MN 55422 ASSEMBLED IN MEXICO S8600M CONTINUOUS RE-TRY 100% SHUTOFF IP Explosion hazard.
- Page 8 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. Models Conn. Ship. Wt. 540A 431 kg...
- Page 9 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 NOTE: TABLE 3. GAS AND ELECTRICAL CHARACTERISTICS Natural <5 Model GPG/GPV-540A GPG/GPV-650A GPG/GPV-740A * Note: ** Note:...
- Page 10 INSTALLATION CONSIDERATIONS LOCATING THE WATER HEATER CAUTION Property Damage Hazard All water heaters eventually leak. Do not install without adequate drainage. CLEARANCES Fire or Explosion Hazard Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. Avoid all ignition sources if you smell gas.
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Page 11: Hard Water
DO NOT HARD WATER CIRCULATION PUMPS FIGURE 7. INSULATION BLANKET CIRCULATING PUMP WIRING DIAGRAM STORAGE TANK OR BUILDING RECIRCULATION Breathing Hazard - Carbon Monoxide Gas FIELD SUPPLIED TEMPERATURE CONTROL INSTALLED IN THE STORAGE TANK OR CIRCULATING LOOP RETURN LINE Do not obstruct water heater air intake NOTE: USE SEPARATE 120 VAC POWER with insulating blanket. - Page 12 HIGH ALTITUDE INSTALLATIONS Fire and Explosion Hazard Under no circumstances should the input exceed the rate shown on the water heater’s rating label. Overfiring could result in fire or explosion. Gas and carbon monoxide detectors are available. Breathing Hazard - Carbon Monoxide Gas Under no circumstances should the input exceed the rate shown on the water heater’s rating label.
- Page 13 INSTALLATION REQUIREMENTS GAS SUPPLY SYSTEMS POWER SUPPLY WATER TEMPERATURE CONTROL AND MIXING VALVES Water temperature over 125°F (52°C) can cause severe burns instantly resulting in severe injury or death. Children, the elderly and the physically or mentally disabled are at highest risk for scald injury.
- Page 14 HOT WATER OUTLET 12” TO 15” (30-38 cm) TEMPERED WATER TEMPERATURE-PRESSURE RELIEF VALVE OUTLET CHECK COLD VALVE WATER INLET Explosion Hazard MIXING CHECK VALVE VALVE Temperature-Pressure Relief Valve must comply with ANSI Z21.22- TO TANK CSA 4.4 and ASME code. INLET Properly sized temperature- pressure relief valve must be...
- Page 15 CONTAMINATED AIR Breathing Hazard - Carbon Monoxide Gas Install water heater in accordance with the Instruction Manual and NFPA 54 or CAN/CSA-B149.1. CAUTION To avoid injury, combustion and ventilation air must be taken from outdoors. Water Damage Hazard Do not place chemical vapor emitting products near water heater.
- Page 16 UNCONFINED SPACE DIRECT VENT APPLIANCES EXHAUST FANS UNUSUALLY TIGHT CONSTRUCTION LOUVERS AND GRILLES CONFINED SPACE VENTING INSTALLATION FRESH AIR OPENINGS FOR CONFINED SPACES OUTDOOR AIR THROUGH ONE OPENING OUTDOOR AIR THROUGH TWO OPENINGS FIGURE 12. FIGURE 11.
- Page 17 OUTDOOR AIR THROUGH TWO HORIZONTAL DUCTS AIR FROM OTHER INDOOR SPACES FIGURE 13. FIGURE 15. OUTDOOR AIR THROUGH TWO VERTICAL DUCTS Do not refer to these illustrations for the purpose of vent VENTING FIGURE 14.
- Page 18 BAROMETRIC DRAFT CONTROL ASSEMBLY HORIZONTAL (SIDE-WALL) VENTING FOR GPV MODELS TABLE 6. NOTE: GPV-540A thru 740A 90° 45° PROPER DRAFT CONTROLLER AND VENT PIPE INSTALLATION FIGURE 16. TABLE 7. VENT CONNECTION Heater Terminal Rough-In Model Model Dimensions Thru TABLE 5. BAROMETRIC DRAFT CONTROL ASSEMBLY OUTLET SIZE Model Flue Outlet...
- Page 19 SIDEWALL TERMINATION INSTALLATION DIRECT VENTING - FOR BTPV MODELS VENT SYSTEM INSTALLATION TABLE 8. Selkirk Metalbestos Model PS CAUTION Clearance to Combustibles Interior Use only the vent hood supplied with this kit. Only supplied hood provides required clearances from combustibles, both through the wall and the exterior siding.
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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 BEWARE OF CONCEALED WIRING AND PIPING INSIDE WALL. REFER TO TABLE 3 FOR THE MAXIMUM WALL THICKNESS “B” FOR EACH MODEL. TABLE 10. Vent Diameter...
- Page 23 FIGURE 19B. FIGURE 19.
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Page 24: Water Heater Installation
WATER HEATER INSTALLATION WATER LINE CONNECTIONS T&P VALVE DISCHARGE PIPE Explosion Hazard Temperature-Pressure Relief Valve must comply with ANSI Z21.22- CSA 4.4 and ASME code. Properly sized temperature- pressure relief valve must be installed in opening provided. Can result in overheating and excessive tank pressure. -
Page 25: Heater Wiring
INSTALLATION DIAGRAMS - TOP INLET/OUTLET USAGE HEATER WIRING TUBE INLET INSTALLATION FIGURE 20. FIGURE 21. - Page 26 FIGURE 22. GAS PIPING...
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Page 27: Purging
GAS METER SIZE – NATURAL GASES ONLY TABLE 11. MAXIMUM CAPACITY OF PIPE IN CUBIC FEET OF GAS PER HOUR GAS PIPING AND SEDIMENT TRAP INSTALLATION NOMINAL IRON PIPE SIZE (INCHES) LENGTH IN FEET 1 1/4 1 1/2 2 1/2 FIGURE 23. - Page 28 START-UP AND OPERATION Fire or Explosion Hazard Gas line purging is required with new piping or systems in which air has entered. To avoid risk of fire or explosion purge discharge must not enter into confined areas or spaces where ignition can occur. The area must be well ventilated and all sources of ignition must be deactivated or removed.
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Page 30: Lighting & Operation Label
LIGHTING & OPERATION 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. Do NOT FIGURE “A”... - Page 31 ADJUSTMENTS Important Note: or O Important Note: If the O Excessive gas line pressure drop and/or burner manifold If the O pressure too low may cause burner start /operate with excessive noise! ADJUSTMENT PROCEDURE FOR FIRE-RATE, LOW NOX AND HIGH ELEVATION (Fine-Tune) Never set burner combustion too lean (causing noisy operation) or too rich (causing combustion chamber premature failure) see Table 3 for proper settings.
- Page 32 PREMIX LOW NOx BURNER - EXPLODED VIEW FOR GPG MODELS FIGURE 25.
- Page 33 PREMIX LOW NOx BURNER - EXPLODED VIEW FOR GPV MODELS FIGURE 26.
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Page 34: Venting
MAINTENANCE VENTING SYSTEM AND BAROMETRIC DRAFT CONTROL TEMPERATURE-PRESSURE RELIEF VALVE TEST BAROMETRIC DRAFT CONTROL FIGURE 27. Pressure Relief Valve GENERAL TABLE 12. RECOMMENDED MAINTENANCE SCHEDULE FOR THE BTP HEATER OPERATION INTERNAL Tank Relief Valve Oiling Quarterly Non-Detergent FIGURE 28. Annually REMOTE STORAGE TANK TEMPERATURE CONTROL... - Page 35 Explosion Hazard TO DRAIN THE WATER HEATER STORAGE TANK: Temperature-Pressure Relief Valve must comply with ANSI Z21.22- CSA 4.4 and ASME code. Properly sized temperature- pressure relief valve must be installed in opening provided. Can result in overheating and excessive tank pressure. Can cause serious injury or death.
- Page 36 Prepare the Water Heater 180°F For 10 Grain Hardness Lime Deposited vs. Temperature and Water Use Data From Purdue Bulletin 74 170°F 160°F Explosion Hazard Flammable hydrogen gases may be present. 150°F Keep all ignition sources away 140°F from faucet when turning on 120°F hot water.
- Page 37 FIGURE 30. POWER BURNER Note: TYPICAL MAIN BURNER FLAME FIGURE 31.
- Page 38 GAS CONTROL VALVE FIGURE 32. SERVICE ELECTRICAL SERVICING TROUBLESHOOTING BURNER LOCKOUT ONCE IN A WHILE 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.
- Page 39 MOTOR RUNS CONTINUOUSLY, PREPURGE TIME ELAPSES ignitor BUT MAIN FLAME NOT ESTABLISHED (BURNER LIGHT NEVER ON) MOTOR RUNS CONTINUOUSLY, BURNER LIGHTS ON MOMENTARILY THEN LOCKS OUT OR EXCESSIVE ON/ OFF CYCLE then pilot gas light...
- Page 40 GAS FAILS TO SHUT OFF NOISY BURNER OPERATION REPLACEMENT PARTS FOR YOUR INFORMATION START UP CONDITIONS SMOKE/ODOR STRANGE SOUNDS CONDENSATION “AIR” IN HOT WATER FAUCETS OPERATIONAL CONDITIONS HIGH WATER TEMPERATURE SHUT OFF SYSTEM HOT WATER ODOR...
- Page 41 WATER PIPING DIAGRAMS...
- Page 51 STORAGE TANK...
- Page 54 STORAGE TANK...
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Page 56: Prior To Start Up
MANIFOLD KITS PRIOR TO START UP IMPORTANT... - Page 57 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 9006187205 9006187205 9006187205 9004529005 9004529005 9004529005 181260 181260 181260 9003906015 9003906015 9003906015 195036-2 195036-1 195036 9005797205 9005797205 9005797205 9004099215 9004099215 9004099215 9004100215 9004100215 9004100215 9500007350 9500007350 9500007350 Item Description GPV-540A GPV-650A GPV-740A 9006187205 9006187205 9006187205 9004529005 9004529005 9004529005...
- Page 59 Service/labor, shipping, delivery, installation, handling or any other costs are not covered at any time under this warranty. LIMITATIONS SERVICE INQUIRIES: For service inquiries call the telephone number listed below. State Water Heaters 500 Tennessee Waltz Parkway Ashland City, Tennessee 37015 800-365-0024 www.statewaterheaters.com...
- Page 60 www.statewaterheaters.com...