State Industries GPG-650A manual

1 MODELS GPG/GPV-540A, 650A AND 740A COMMERCIAL GAS, GLASS-LINED, TANK-TYPE LOW NOx WA TER HEA TER P ART NO. 195047-000 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 , T N www.statewaterheaters.com PLACE THESE INSTRUC[...]

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 certified under UL 795. Detailed installation diagrams are found in thi[...]

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 with Liquefied Petroleum or LP gas. If you have obtained a GPG/GPV-540A, 650A or 740A model with the intent to u[...]

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 , uncont aminated air should be obtained from remote or out[...]

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 flooring, 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 co[...]

7 Heater must be protected from freezing downdrafts during shutdown periods. The GPG 540A, 650A and 750A water heater are classified as a category I appliance (non-positive vent pressure, non- condensing) when installed with the supplied barometric draft control assembly in a vertical vent installation. The GPV 540A through 740A heater is classifie[...]

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, flue reducer , and intake vent terminal are supplied with any unit intended for direct 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 of su[...]

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 s[...]

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 grooves in both inner vee bands with high-temp silicone sealant, Dow Corning 736 or equivalent. 7. Position the inner vee bands around the inner pipe flanges and [...]

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 Water Column and 0.5 Specific Gravity Gas and max. gas press. of .5 psig) LENGTH I N Nominal Iron Pipe Sizes, Millimeters METERS 1/2" 3/4" 1" 1 1/4" 1 1/2" 2 " 2 1/2" 3" 4 " 3.0 51 105 199 410 615[...]

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 THERMAL EXP ANSION OF W A TER IN THE HOT W A TER SYSTEM MUST BE PROVIDED. NOT[...]

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 NOTE: IF TEMPERED WA TER IS RECIRCULA TED, RETURN LINE SHOULD BE CONNECTED A T POINT “A”. INSTA LL IN ACCORDANCE WITH LOCAL CODES[...]

16 CAUTION: IF BUILDING COLD W A TER SUPPL Y HAS A BACKFLOW PREVENTER, CHECK V ALVE OR W A 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 (ON[...]

17 TWO TEMPERA TURE - ONE HEA TER HIGH TEMPERA TURE WITH RECIRCULA TION OF SANITIZING LOOP CAUTION: IF BUILDING COLD W A 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 ATER 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 flow balance of all units. Without this balance, the full water heating and storage potential of the system cannot be achieved. Plus, the units with the higher water flow may have a shortened life. Unions shown in piping diagrams are not included in the manifold[...]

19 HEA TER WIRING IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED, IT MUST BE REPLACED WITH 105°C WIRE OR ITS EQUIV ALENT , EXCEPT IN THE 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 provided the ele[...]

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: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance is equipped with an ignition de[...]

23 SEQUENCE OF OPERA TION – Power on. – Heater in standby mode. – Thermostat calls for heat. – Blower motor starts. – Blower operation closes the normally open blower prover/ blocked outlet safety pressure switch. – On proof of airflow , Honeywell S8680J flame control module energized. – 45 seconds prepurge cycle begins. – Following[...]

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 Troubleshooting refer to the s[...]

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. Turn 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 ABOVE ALL, DO NOT PLUG THE TEMPERA TURE AND 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 AROUND THE BURNER C[...]

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 and the troubleshooting section of burner manual before continuing. Make sure the appliance is connected to a 120 V ac power supply , burner switch is “ON” and manual gas valve is in the “ON” position, and all electrical connections are secure before continuing to troubleshoot this appliance. MOTOR WILL NOT RUN 1. Confirm 120 V ac. Also,[...]

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

33 Model GPG/GPV Limited W arranty S t ate Industries, Inc. , the warrantor , extends the following LIMITED W ARRANTY to the owner of this water heater . 1. THE T ANK If the glass-lined tank in this water heater shall prove upon examination by the warrantor to have leaked due to the natural corrosion from potable water therein, during the first THR[...]

34 COMMERCIAL TANK TYPE WATER HEATER REPLACEMENT PARTS LIST MODELS GPG/GPV-540A THRU 740A 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 CLEANOUT ASSEMBL Y 11 C 11 B 11 A 11 4 BAROMETRIC DRAFT CONTROL RELIEF VA LV E 12 9B 9A (P[...]

35 GPG GPV Item Description GPG-540A GPG-650A GPG-740A 1 ........ Anode, Plug ........................................................................ 183523-48(4) ............... 183523-48(4) ................ 83523-48(4) 2 ........ Baffle, Flue ........................................................................... 194974(16) .................[...]

36 GPG BURNER ASSEMBL Y (Part numbers are listed on page 37)[...]

37 GPG GPG GPG GPG Item Description GPG-540A GPG-650A GPG-740A 1 ....... Ignition Control . .. .. .. .. .. . .. .. .. .. .. ............................................................ 6207 ............................. 6207 ............................ 6207 2 ....... Motor - 1/4 HP 3450 RPM .........................................................[...]

38 GPV BURNER ASSEMBL Y (Part numbers are listed on page 39)[...]

39 GPV GPV GPV GPV Item Description GPV-540A GPV-650A GPV-740A 1 ....... Ignition Control . .. .. .. .. .. . .. .. .. .. .............................................................. 6207 ............................. 6207 ............................ 6 20 7 2 ....... Motor - 1/4 HP 3450 RPM ........................................................[...]

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