State Industries 540A manual

1 MODELS GPG/GPV -540A, 650A AND 740A COMMERCIAL GAS, GLASS-LINED, T ANK-TYPE LOW NOx W A TER HEA TER 1 95047 - 00 1 CAUTION TEXT IN BLACK BOLD TYPE OR UNDERLINED CONT AINS INFORMA TION RELA TIVE TO YOUR SAFETY . PLEASE READ THOROUGHL Y BEFORE INST ALLING AND USING THIS APPLIANCE . ASHLAND CITY , TN www .statewaterheaters.com PLACE THESE INSTRUCTIO[...]

2 FOREWORD The design of the GPG 540A through 740A models complies with ANSI Z21.10.3/CSA 4.3 as an automatic circulating tank and an automatic instantaneous type heater . The GPV 540A through 740A models are designed for sidewall venting and direct venting applications and are certied under UL 795. Detailed installation diagrams are found in th[...]

3 are different from natural gas models. A natural gas heater will not function safely on LP gas and no attempt should be made to convert a heater from natural gas to LP gas. GPG/ GPV -540A, 650A & 740A models are not available for use     ?[...]

4 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. If necessary , uncontaminated air should be obtained from remote or outs[...]

5 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[...]

6 Units, which are to be installed on combustible ooring, 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 c[...]

7 Heater must be protected from freezing downdrafts during shutdown periods. The GPG 540A, 650A and 750A water heater are classied as a cate gory I appli ance (non -pos itiv e vent press ure, non-con dens ing) when installed with the supplied barometric draft control assembly in a vertical vent installation. The GPV 540A through 740A heater is c[...]

8 Refer to T able 2 for limitations of venting system design for horizontal venting. T ABLE 2 GPV -540A-740A Flue Outlet Dia. (Inches/mm) 9” (228.6) Flue Reducer 9” x 8” Dimensions -Supplied (Inches/mm) 228.6 x 203.2 Minimum Outlet V ent Dia. (Inches/mm) 8” (203.2) Maximum Number 90° 4 Of Elbows 45° 8 Maximum T otal V ent System 75 Length[...]

9 DIRECT VENTING - FOR GPV MODELS All exhaust vent terminal, ue reducer , and intake vent terminal are suppl ied with any unit intende d for direc t venting . These parts must be installed without alteration. This heater is category III appliance when used in a direct vent application. All national and local codes pertaining to the installation [...]

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. Shall be located 12” (304.8 mm) above the snow line in geographical areas where sn[...]

11 5. 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. 6. Fill the gro ov es in both inne r vee bands with high -t emp sili con e sealant, Dow Corning 736 or equivalent. 7. Position the inner vee bands around the inner pipe an[...]

12 T ABLE 9A MAXIMUM CAP ACITY OF PIPE IN CUBIC FEET OF GAS PER HOUR (Based upon a Pressure Drop of 0.5 inch W ater Column  LENGTH IN Nominal Iron Pipe Sizes, Millimeters ME[...]

13 ROBERTSHA W ® 7000 DERHC GAS CONTROL V AL VE FIGURE 10. W A TER 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, [...]

14 INST ALLA TION DIAGRAMS ONE TEMPERA TURE - ONE HEA TER VERTICAL STORAGE T ANK FORCED CIRCULA TION WITH OR WITHOUT BUILDING RECIRCULA TION DANGER IF BUILDING COLD W A TER SUPPL Y HAS A BACKFLOW PREVENTER, CHECK V AL VE OR W A TER METER WITH CHECK V AL VE, PROVISIONS FOR THER MAL EX P ANSION OF W A TER IN THE HOT W A TER SYSTEM MUST BE PROVIDED. N[...]

15 TWO TEMPERA TURE - ONE HEA TER HIGH TEMPERA TURE WITH OR WITHOUT BUILDING RECIRCULA TION TWO TEMPERA TURE - TWO HEA TERS HIGH TEMPERA TURE WITH OR WITHOUT BUILDING RECIRCULA TION *PIPE RELIEF V AL VE TO OPEN DRAIN N O T E : IF TEMPERED W A TER IS RECIRCULA TED, RETURN LINE SHOULD BE CONNECTED A T POINT “A”. INST ALL IN ACCORDANCE WITH LOCAL [...]

16 CAUTION: IF BUILDING COLD WA TER SUPPL Y HAS A BACKFLOW PREVENTER, CHECK V AL VE OR WA TER METER WITH CHECK V AL VE, PROVISIONS FOR THERMAL EXP ANSION OF W A TER IN THE HOT W A TER SYSTEM MUST BE PROVIDED. TWO TEMPERA TURE - THREE HEA TERS (TWO PRE-HEA TERS/ONE BOOSTER) WITH OR WITHOUT BUILDING RECIRCULA TION TWO TEMPERA TURE - TWO HEA TERS (ONE[...]

17 TWO TEMPERA TURE - ONE HEA TER HIGH TEMPERA TURE WITH RECIRCULA TION OF SANITIZING LOOP CAUTION: IF BUILDING COLD WA TER SUPPL Y HAS A BACKFLOW PREVENTER, CHECK V AL VE OR WA TER METER WITH CHECK V AL VE, PROVIS IONS FOR THERMAL EXP ANSION OF WA TER IN THE HOT WA TER SYSTEM MUST BE PROVIDED. DANGER TEMPERA TURE SETTING SHOULD NOT EXCEED SAFE TEM[...]

18 MANIFOLD KITS Precision cut type “L” all copper State manifold kits assure water ow balan ce of all units . Wit hou t this balan ce, the full water heati ng and storage potential of the system cannot be achieved. Plus, the units with the higher water ow may have a shortened life. Unions shown in piping diagrams are not included in the [...]

19 HEA TER WIRING IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED, IT MUST BE REPLACED WIT H 1 05 °C WIRE O R I TS EQUI V AL EN T , E XC EPT I N TH E BURNER HOUSING USE 200°C WIRE. The power burner is wired to the heater as shown in Figure 1 1 for GPG models and Figure 12 for GPV models. The model and rating plate prov[...]

20 FIGURE 1 1.[...]

21 FIGURE 12.[...]

22 FOR YOUR SAFETY READ BEFORE LIGHTING 1. Remove thermostat control cover . 2. Set thermostat to lowest setting. 3. Turn burner switch to “OFF”. W ARNING:             expl[...]

23 DANGER TH IS W A TE R H E A TE R I S E QUI P PE D W ITH AN AD JUS T AB LE TH ER MO ST A T T O C ON TR OL W A TER TEM PE RA TURE . HO T W A TER TEMPERA TURES REQUIRED FOR AUTOMA TIC DISHW ASHER AND LAUNDRY USE CAN CAUSE SCALD BURNS RE SUL TI N G IN S ERI OU S PER SON AL IN JU R Y AN D /O R DE A TH . T HE TE M PE RA TU R E A T WH IC H IN JU R Y O [...]

24 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” w .c. when heater main gas is “ON”. Check heater ga[...]

25 PREMIX LOW NOx BURNER - EXPLODED VIEW FOR GPG MODELS FIGURE 13.[...]

26 PREMIX LOW NOx BURNER - EXPLODED VIEW FOR GPV MODELS FIGURE 14.[...]

27 GENERAL INFORMA TION 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. For detailed Power Burner Operation, Maintenance and T roubleshooting refer to the [...]

28 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. T urn off the heater electrical disconnect switch. 2. Close the cold water inlet valve to heater . 3. Open a nearby hot water faucet to vent the system. 4. Open the heater[...]

29 A B O V E A L L, D O N O T P L U G T H E T E MP E RATU RE AN D PRESSURE RELIEF V AL VE. THIS IS NOT A SOLUTION AND CAN CREA TE A HAZARDOUS SITUA TION. CIRCULA TING PUMP The water heating system may include a circulating pump. Where used, it should be lubricated as directed by the circulator manufacturer . LOW EMISSION POWER BURNER KEEP THE AREA [...]

30 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. • If the heater was installed when incoming water temperature was [...]

31 20 , an d the troubleshooting section of burner manual before continuing. Make sure the appliance is connected to a 120 V ac power supply , burne r switch is “ON” and manual gas valve is in the “ON” posit ion, and all electrical connections are secure before continuing to troubleshoot this appliance. MOTOR WILL NOT RUN 1. Conrm 120 V [...]

32 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. • T urn the burner switch to “OFF” position for at least one minute to reset the heater . • Check for 24V between “PV” terminal and “MV/PV” te[...]

33 Model GPG/GPV Limited W arranty Factory Start-Up is required for activat ing warran ty and assuring maximu m operatin g performa nce. Contact your local sales representa tive or Authoriz ed Start-Up Agent to arrange a FREE Certied Start-Up. State Industries, Inc., the warrantor , extends the following LIMITED WARRANTY to the owner of this wat[...]

34 COMMERCIAL T ANK TYPE W A TER HEA TER REPLACEMENT P ARTS LIST MODELS GPG/GPV -540A THRU 740A SERIES 104 ST A TE W A TER HEA TERS 500 Lindahl Parkway , Ashland City , TN 37015  website: www .statewaterheaters.com GPV VENT [...]

35 1......... Anode, Plug ...................................................................... 9003892005(4) ............ 9003892005(4) ............. 9003892005(4) 2......... Bafe, Flue .......................................................................9006832005(24) .......... 9006832005(24) ........... 9006832005(24) 3......... V alve, R[...]

36 GPG BURNER ASSEMBL Y (FOR ALL P ARTS ON THIS BURNER CONT ACT : W ayne Combustion Systems, 801 Glasgow Ave, Fort W ayne IN 46803)[...]

37 500 Lindahl Parkway , Ashland City , TN 37015 Phone: 800-821-2017 Fax: 800-644-9306 www .statewaterheaters.com[...]