State Water Heaters GPG-540A, Installation Operation & Maintenance

Page 1: ...BOLD TYPE OR UNDERLINED CONTAINS INFORMATION RELATIVE TO YOUR SAFETY PLEASEREADTHOROUGHLYBEFORE 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 INSTALLATION OPERATION MAINTENANCE LIMITED WARRANTY PRINTED IN U S A 1004 ...

Page 2: ...ODELS HORIZONTAL DIRECTVENTING GPVMODELS ALLDIMENSIONSININCHES MILLIMETERS Gas Approx Models A B C D E F G H I Conn Ship Wt GPG GPV 80 3 4 73 32 1 4 9 6 26 1 2 93 29 1 2 48 1 2 1 950 540A 2 051 1 854 819 229 152 673 2 362 749 1 232 25 4 431 kg GPG GPV 80 3 4 73 32 1 4 9 8 26 1 2 93 29 1 2 48 1 2 1 950 650A 2 051 1 854 819 229 203 673 2 362 749 1 232 25 4 431 kg GPG GPV 80 3 4 73 32 1 4 9 8 26 1 2 ...

Page 3: ...uired Ability 5 Uncrating 5 Locating the Heater 5 6 Hard Water 6 Clearances 6 Air Requirements 6 Venting 6 7 Vertical Venting For GPG Models 7 Horizontal Side wall Venting For GPV Models 7 8 Direct Venting For GPV Models 9 11 Gas Piping 11 12 Gas Meter Size 12 Gas Pressure Regulation 12 Gas Valves 12 13 Water Line Connections 13 Thermometers 13 Relief Valve 13 INSTALLATION DIAGRAMS 14 17 Manifold ...

Page 4: ...ERED WITH STORAGE TANK WATER HEATER YOUR STATE WATER HEATER MEETS OR EXCEEDS THE ASHRAE IES 90 1B 2001 STANDARDS WITH RESPECT TO INSULATION AND STANDBY LOSS REQUIREMENTS MAKING AN INSULATION BLANKET UNNECESSARY THE USE OF INSULATION BLANKETS IN CONJUNCTIONWITHASTATEWATERHEATERWILLALSOVOID THESTATE WARRANTYFORTHEFOLLOWINGREASONS 1 INSULATION BLANKETS COVER IMPORTANT OPERATING INSTRUCTIONSANDSAFETYL...

Page 5: ...ne 1 flue reducer The intake vent hood carton contains one 1 intake vent hood and one 1 inlet adapter All parts should be installed as received without alteration LOCATING THE HEATER When installing the heater consideration must be given to proper location Location selected should be as close to the stack chimney as practicable with adequate air supply and as centralized with the piping system as ...

Page 6: ...SUCHACONDITIONOFTENWILLRESULT IN A YELLOW LUMINOUS BURNER FLAME CAUSING CARBONING OR SOOTING OF THE COMBUSTION CHAMBER BURNERS AND FLUE TUBES AND CREATES A RISK OF ASPHYXIATION Where an exhaust fan is installed in the same room with a heater sufficient openings for air must be provided in the walls UNDERSIZEDOPENINGSWILLCAUSEAIRTOBEDRAWNINTO THE ROOM THROUGH THE CHIMNEY CAUSING POOR COMBUSTION SOO...

Page 7: ...ng system Refer to Table 1 for the vent pipe size required for installation to the barometric draft control assembly outlet TABLE1 Model Flue Outlet 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 All local and utility regulations on venting must be followed NOTE ANEGATIVE DRAFTMUST BE MAINTAINE...

Page 8: ...portions of the vent system must be installed with a minimum upward slope of 1 4 per foot of length All joints and seams in the venting system must be sealed gas tight If a silicone sealer is used it must have a continuous temperature rating of at least 500 F 260 C Dow Corning 736 or equivalent must be used CAUTION Use only the vent hood supplied with this kit Only supplied hood provides required ...

Page 9: ...ng must be adequately supported to avoid unnecessary stress on vent hood venting or burner See Table 5 limitations on venting system design for direct vent installations TABLE5 Dimension in GPV Inches mm 540A 740A Flue Outlet Dia 9 229 Flue Reducer Dimension 9 x 8 Supplied 229 x 203 Min Exhaust Vent Dia Inch mm 8 203 Min Intake Vent Dia Inch mm 8 203 Maximum Number Of 90 4 Elbows Intake 45 8 Maxim...

Page 10: ...r 3 feet 9144 m vertically from gas line meter or other gas supply entering a structure see Figure 6 FIGURE 7 DIRECTVENTSYSTEMINSTALLATION Plan the vent system backwards from the vent hood to the heater 1 Use the inside wall cover plate as a template to mark two holes in the appropriate places on the wall Cut holes 1 2 12 7 mm larger to facilitate easy installation of vent hoods see Figures 6 and ...

Page 11: ...Prime and cement each joint to assure gas tight construction 16 Seal all joints at the vent hoods with silicone sealant Also seal the joints at the flue collar and air inlet adapter Joint on the exhaust side must be sealed with high temp silicone sealant Dow Corning 736 or equivalent WARNING PRIMERSAND CEMENTSARE EXTREMELYFLAMMABLE AND MUSTNOTBESTOREDORUSEDNEARHEATOROPENFLAME ALLOWADEQUATECURINGTI...

Page 12: ... 10 THE DIRT LEG MUST BE READILYACCESSIBLEAND NOT SUBJECT TO FREEZING CONDITIONS INSTALL IN ACCORDANCE WITH RECOMMENDATIONS OF SERVING GAS SUPPLIERS REFER TO THE NATIONAL FUEL GAS CODE To prevent damage care must be taken not to apply too much torque when attaching gas supply to gas valve inlet Apply joint compounds pipe dope sparingly and only to the male threads of pipe joints Do not apply compo...

Page 13: ...ters should be obtained and field installed as shown in the installation diagrams Thermometers are installed in the system as a means of detecting the temperature of the outlet water supply RELIEF VALVE This heater is equipped with an approved temperature and pressure relief valve ASME ratings cover pressure relief A G A ratings cover release rate with temperature actuation FOR SAFE OPERATION OF T...

Page 14: ... USED TO COLD WATER INLET LINE ONE TEMPERATURE ONE HEATER HORIZONTALSTORAGE TANK FORCED CIRCULATION WITH OR WITHOUT BUILDING RECIRCULATION 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 ...

Page 15: ...AUTION 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 WIRING DIAGRAM FOR TEMPERED WATER LOOP IF USED CIRCULATINGPUMPWIRINGDIAGRAM DANGER TEMPERATURE SETTING SHOULD NOT EXCEED SAFE TEMPERATURE AT FIXTURES SEE WATER TEMPERATURE CONTROL WARNING ON PAGE 23 IF HIGHER PR...

Page 16: ...PIPE RELIEF VALVETO OPEN DRAIN 140 F TO 150 F SHOULD BE MAXIMUM WATERTEMPERATUREMAINTAINEDINTHE PRE HEATERS 120 F SHOULD BE THE MINIMUM TEMPERATURE OF WATER IN THE PRE HEATERS CONNECT CIRCULATING LINE FROM FIXTURES IF USED TO COLD WATER SUPPLY LINE OF PRE HEATER CONNECTCIRCULATINGLINEOF180 FORBOOSTED WATER IFUSED TOINLETWATERLINETOBOOSTER INSTALLINACCORDANCE WITH LOCALCODES DANGER TEMPERATURE SETT...

Page 17: ...STER OUTPUT ADD AN ANTI SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES PIPE TO OPEN DRAIN INSTALL IN ACCORDANCE WITH LOCAL CODES NOTE 1 TOGGLE SWITCH CONTROLS 180 WATER CIRCULATION INSTALL ON OR CLOSE TO DISHWASHING MACHINE TOGGLESWITCHMUSTBECLOSED ON DURINGTHERINSE OPERATIONAND OPEN OFF WHEN DISHWASHER IS NOT OPERATING OR WHEN ON LONG STANDBY NOTE 2 INSTALLLINETEMPERATURECONTROLINANUNINSULATED TE...

Page 18: ...pied by the water heaters assemblies Space for the barometric draft control assemblies combustion clearances and servicing must be added WARNING FAILURE TO PROPERLY MANIFOLD MULTIPLE WATER HEATERSAND PROVIDEADEQUATE STORAGE CAPACITY IN ACCORDANCEWITHPROPERSIZINGTECHNIQUESCANRESULT INIMPROPEROPERATIONANDPOSSIBLEFIRERESULTINGIN PROPERTY DAMAGE PERSONAL INJURY OR DEATH HEATERS SHOULD BE MANIFOLDED IN...

Page 19: ... HEATERAND PIPING NEVER OPERATE THE HEATER WITHOUT FIRST BEING CERTAIN IT IS FILLED WITH WATER AND A TEMPERATURE AND PRESSURE RELIEF VALVE IS INSTALLED IN THE RELIEF VALVE OPENING OF THE HEATER FILLING 1 Close the heater drain valve by turning handle clockwise 2 Open a nearby hot water faucet to permit the air in the system to escape 3 Fully open the cold water inlet pipe valve allowing the heater...

Page 20: ...20 FIGURE 11 ...

Page 21: ...21 FIGURE 12 ...

Page 22: ...se to lowest setting 3 Turn off all electric power to the appliance 4 This appliance is equipped an ignition device which automatically lights the burner Do NOTtry to light the burner by hand 5 Refer to diagrams above Turn top knob of gas control clockwise to OFF position Figure A 6 Wait five 5 minutes to clear out any gas If you then smell gas STOP Follow B in the safety information above on this...

Page 23: ...R TEMPERATURES REQUIRED FOR AUTOMATIC DISHWASHERANDLAUNDRYUSECANCAUSESCALDBURNS RESULTING IN SERIOUS PERSONALINJURYAND OR DEATH THE TEMPERATUREAT WHICH INJURYOCCURS VARIES WITH THE PERSON S AGE AND TIME OF EXPOSURE THE SLOWER RESPONSETIMEOFCHILDREN AGEDORDISABLEDPERSONS INCREASES THE HAZARDS TO THEM NEVER ALLOW SMALL CHILDREN TO USE A HOT WATER TAP OR TO DRAW THEIR OWN BATH WATER NEVER LEAVE A CHI...

Page 24: ...2 reading Increase air damper setting will decrease fire rate and decrease flue gas CO2 reading Adjustable air damper is preset for the rated fire rate prior to delivery should not be re adjusted unless it s a high elevation application and or a direct vent long air intake vent application 1 Fire Rate Adjustment including direct vent installation a Make sure the gas supply line pressure reads 8 w ...

Page 25: ...25 PREMIX LOW NOx BURNER EXPLODED VIEW FOR GPG MODELS FIGURE 13 ...

Page 26: ...26 PREMIX LOW NOx BURNER EXPLODED VIEW FOR GPV MODELS FIGURE 14 ...

Page 27: ...GASOLINEANDOTHERFLAMMABLEVAPORSAND LIQUIDS SEE WARNING PAGE 6 Water heater maintenance includes periodic tank flushing and cleaning and removal of lime scale The power burner should be inspected and adjusted to maintain proper combustion Refer to the following table A periodic inspection of the venting system should be made Where used the water heating system circulating pump should be oiled MAINT...

Page 28: ...he more stubborn mineral deposits State UN LIME Professional delimer should be used State UN LIME Delimer is an easy to handle patented food grade acid formulated specifically for lime scale removal from all types of water using equipment Available in 1 gallon part no 4763 and 5 gallon part no 4813 sizes Hydrochloric base acids are not recommended for use on glass lined tanks State Form No 4800 en...

Page 29: ...which are an integral part of the combustion chamber as damage could occur The flue passages are 48 1 2 1 232 mm long x 3 76 2 mm diameter 8 Upon completion of cleaning return heater to operation by following this procedure in reverse BAROMETRIC DRAFT CONTROL FOR GPG MODELS The heater is equipped with a double acting barometric draft control as shown in Figure 15 The damper gate must pivot freely ...

Page 30: ... 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 Ins...

Page 31: ...ween the flame rod and sensor connection at Honeywell flame control module by the ohm meter Check for ignitor wire connections and spark leakage call AOS service center for steps of spark leakage checking Following burner manual instructions to re install the pilot assembly 6 Turn on the Robertshaw gas valve turn the burner switch to ON position Cycle the heater ON OFF several times to ensure the ...

Page 32: ...RRUNSCONTINUOUSLY BURNERLIGHTSON MOMENTARILYTHENLOCKSOUTOREXCESSIVE ON OFFCYCLE Under this condition the burner will start the purge cycle again then pilot ignition and main flame cycle If main flame cannot be sustained 1 Make sure main manual gas valve right after the Robertshaw gas valve is fully open 2 Check for 24V at the Robertshaw gas valve when the main gas light is on If there s no 24V at ...

Page 33: ...alled in the cold water supply the heater is connected to unless an effective method of controlling thermal expansion is also installed at the heater s and operational at all times The relief valve installed on the heater is not an acceptable method 4 SERVICEAND REPAIR EXPENSES Under the limited warranty the warrantor will provide only a replacement water heater or part thereof The owner is respon...

Page 34: ... SERIES 104 STATE WATER HEATERS 500 Lindahl Parkway Ashland City TN 37015 Phone 1 800 821 2017 Fax 1 800 6449306 website www statewaterheaters com GPV VENT KIT 9 CLEANOUTASSEMBLY 11C 11B 11A 11 4 BAROMETRIC DRAFTCONTROL RELIEF VALVE 12 9B 9A Part numbers are listed on page 35 8 3 4 5 6 7 10 ...

Page 35: ... GPV 740A 1 Anode Plug 183523 48 4 183523 48 4 83523 48 4 2 Baffle Flue 194974 16 194974 16 194974 16 3 Cover Jacket 195046 195046 195046 4 Valve Relief 99465 3 99465 3 99465 3 5 ThermostatW E C O 192828 192828 192828 6 Cover Front 181260 181260 181260 7 Valve Drain 26273 6 26273 6 26273 6 8 Jacket Base 195045 195045 195045 9 GPV Vent Kit 192049 1 192049 192049 includes the following items 2 piece...

Page 36: ...36 GPG BURNER ASSEMBLY Part numbers are listed on page 37 ...

Page 37: ...6207 23 6207 23 6207 23 27 Air Staging Band 6207 24 6207 24 6207 24 28 Frame Motor Plate 6207 25 6207 25 6207 25 29 Damper Stop 6207 26 6207 26 6207 26 30 90 Degree Adapter Ass y 6207 27 6207 27 6207 27 31 Housing Ass y 6207 28 6207 28 6207 28 32 Back Mount Panel Ass y 6207 29 6207 29 6207 29 33 Premix Air Housing Wheel 6207 30 6207 30 6207 30 34 Panel Box Door 6207 31 6207 31 6207 31 35 Pie Dampe...

Page 38: ...38 GPV BURNER ASSEMBLY Part numbers are listed on page 39 ...

Page 39: ...7 27 6207 27 31 Housing Ass y 6207 28 6207 28 6207 28 32 Back Mount Panel Ass y 6207 29 6207 29 6207 29 33 Premix Air Housing Wheel 6207 30 6207 30 6207 30 34 Panel Box Door 6207 31 6207 31 6207 31 35 Pie Damper Inner Plate 6207 32 6207 32 6207 32 36 PieDamperMiddlePlate 6207 33 6207 33 6207 33 37 Outer Pie Damper 6207 34 6207 34 6207 34 38 Air Intake Kit 6207 48 6207 48 6207 48 39 Wheel 6207 36 6...

Page 40: ...40 500 Lindahl Parkway Ashland City TN 37015 Phone 800 821 2017 Fax 800 644 9306 www statewaterheaters com ...