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State Industries GPG-650A Water Heater User Manual

1. 12 Gas ValV8S nietos Hbi nie execs 12 13 Water Line COMNECHONS caa eese 13 Thertmotmeters us ecu rne ent tnn nahen 13 Relief Valve sssssssssessesseeeeee nnne nennen nnne nnns 13 INSTALLATION DIAGRAMS 44 111 14 17 Manifold Kits orecchie eet 18 GENERAL SAFETY INFORMATION PRECAUTIONS DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN UNDER WATER Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water IF THE UNIT IS EXPOSED TO THE FOLLOWING DO NOT OPERATE HEATER UNTIL ALL CORRECTIVE STEPS HAVE BEEN MADE BY A QUALIFIED SERVICEMAN EXTERNAL FIRE DAMAGE FIRING WITHOUT WATER SOOTING I om LIQUID PETROLEUM MODELS A WARNING Water heaters for propane or liquefied petroleum gas LPG In the absence of local codes the installation must conform with the instructions as outlined in the latest publication of National Fuel Gas Code NFPA 54 ANSI 2223 1 and National Electric Code NFPA 70 These manuals can be purchased from the Canadian Standards Association Laboratories 8501 East Pleasant Valley Road Cleveland OH 44131 National Fire Protection Association 1 Batterymarch Park Quincy MA 02269 Heater Wiring START UP nu Important Filling Wiring Diagram eara rint r
2. MOUNTED 4 1 2 m MIN HORIZONTALLY AWAY VENT HOOD 7 2 1 m MINIMUM ABOVE WALKWAY VENT HOOD 4 1 2 m MIN 9144 m ABOVE ANY OUTSIDE AIR INTAKE WITHIN 10 VENT HOOD MUST BE MOUNTED 4 1 2 m MIN BELOW WINDOWS 3 0 FIGURE 6 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 Ill appliance when used in a direct vent application All national and local codes pertaining to the installation of such an appliance must be followed Horizontal portions of the exhaust vent system must be installed with a minimum upward slope of 1 4 6 35 mm per foot of length Selkirk metalbestos model PS or G vent is approved for use as exhaust venting on these models Model PS is a double wall vent with a 1 25 4 mm air space between pipes Model G is a single wall variation of model PS for use where combustible clearance is not a concern see Table 4 TABLE 4 Selkirk Metalbestos Model PS Clearance to Combustibles 8 1524 mm 6 152 4 mm 8 diameter PVC or galvanized pipe is approved for use as intake venting on these models Class 63 100 125 200 and schedule 40 pipe may be used for PVC pipe Intake venting must be adequately supported to avoid unnecessary stress on vent hood venting
3. If there s no voltage check for 24V between the air switch COM terminal and GND the air switch is mounted on the control panel the switch cover needs to be removed to access the wiring terminal COM and NO If there s no 24 V check for a loose connection between the 24V transformer and air Switch or a defective transformer If there s 24V at COM terminal check for 24V between the air switch terminal NO normally open and GND If there s no 24V the air switch pressure may be set too high or a defective air switch or loose connections of pressure sensing tubings To lower the air switch setting make sure the blower is running and blower wheel and air inlet are free from dirt counterclockwise turn the switch setting screw until the switch is closed Call the State Technical Center before you reset the switch If there s 24V at NO terminal of the air switch check for 24V at the air intake pressure switch connectors this switch is only supplied for direct vent systems If there s no 24V at the switch connectors check for loose connections air intake blockage or a defective air switch Do not proceed to Step 5 unless 24V is detected at 24V terminal of the Honeywell Module 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 posi
4. A warming of ambient conditions associated with seasonal change could magnify the stacking process described above to the point where high limit switch operation would occur Contact your dealer or servicer if continued high limit switch operation occurs DISHWASHING MACHINE REQUIREMENT All dishwashing machines meeting the National Sanitation Foundation requirements are designed to operate with water flow pressures between 15 and 25 pounds per square inch Flow pressures above 25 pounds per square inch or below 15 pounds per square inch will result in improperly sanitized dishes Where pressures are high a water pressure reducing or flow regulating control valve should be used in 180 F 82 C line to the dishwashing machine and should be adjusted to deliver water between these limits The National Sanitation Foundation also recommends circulation of 180 F 82 C water Where this is done the circulation should be very gentle so that it does not cause any unnecessary turbulence inside the water heater The circulation should be just enough to provide 180 F 82 C water at the point of take off to the dishwashing machine Adjust flow by means of the plug cock in the circulating line INSTALLATION INSTRUCTIONS REQUIRED ABILITY INSTALLATION OR SERVICE OF THIS WATER HEATER REQUIRES ABILITY EQUIVALENT TO THAT OF A LICENSED TRADESMAN IN THE FIELD INVOLVED PLUMBING AIR SUPPLY VENTING GAS SUPPLY AND ELECTRICAL WORK ARE REQUIR
5. AIR DAMPER Haras SETTING AUTO VALE TO PILOT TO LOW GAS H VALVE PRESSURE a PILOT GAS REGULATOR SWITCH L uu 1 lt lit TO PILOT 4 SHUTOFF PRESSURE Kama TEST PORT BN ASSEMBLY 2 THERMAL CUT OFF amp IGNITOR TO TEE ON PILOT MANIFDLD REGULATOR PRESSURE 9 pe ya B Salg MAIN GAS f B MANUAL 1 SHUT OFF PILOT GAS MAIN GAS MANUAL AUTO VALVE SHUT OFF GAS INLET PRESSURE PORT PREMIX LOW NOx BURNER EXPLODED VIEW FOR GPG MODELS FIGURE 13 25 AIR DAMPER STOP TABS SWITCH LOW 7 GAS FLUE PRESSURE 2 1 SWITCH AIR INTAKE BLOWER SWITCH PRESSURE N N GAS PRESSURE SWITCH FROM PILOT SHUTOFF COCK THERMAL CUT OFF IGNITOR TO TEE ON PILOT REGULATOR MANIFOLD PRESSURE BURNER ON OFF SWITCH FLAME CONTROL MODULE FROM PILOT VALVE PRESSURE TEST PORT PILOT GAS MAIN GAS N e MANUAL SHUT OFF AUTO VALVE GAS INLET PRESSURE PORT PREMIX LOW NOx BURNER EXPLODED VIEW FOR GPV MODELS FIGURE 14 26 GENERAL INFORMATION 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 ref
6. Brass Tube 1 4 X 1 8 Std Hardware Purchase Locally 2 Std Hardware Purchase Locally Std Hardware Purchase Locally Pipe Plug 1 1 4 Drilled amp Tapped Orifice Spring Junction Box Junction Box Cover Ball Valve 1 Pilot Ass y Includes Items 8 9 amp 10 Air Staging Band Frame Motor Plate Damper Stop 90 Degree Adapter Ass y 6207 27 6207 27 Housing Ass y 6207 28 6207 28 Back Mount Panel Ass y Premix Air Housing Wheel Panel Box Door Pie Damper Inner Plate 6207 32 Pie Damper Middle Plate 6207 33 6207 33 Outer Pie Damper 6207 34 6207 34 Wheel Amber Light Std Hardware Purchase Locally Flat Washers 3 8 6207 49 6207 49 Tubing to FP 90 70 42 1 4 X 1 8 6207 50 6207 50 El Fitting 1 4 X 1 8 6207 40 Hex Nipple 1 4 Ball Valve Model 740 1 4 Std Hardware Purchase Locally Orifice Aluminum 1 1 4 Std Hardware Purchase Locally Conduit Clamp 6207 43 6207 43 Premix Diffuser Ass y 6207 53 6207 53 Pilot Tubing 3 Rocker Switch O Ring Seal Plastic Cap SC 1 1 Pipe GPG 740A 6207 27 6207 28 6207 33 6207 34 6207 49 6207 50 6207 43 6207 53 GPV BURNER ASSEMBLY Part numbers are listed on page 39 FITTING LE ROTATED ae 227 TO ITEM 43 180 FOR Ere ON LOW GAS VIEWING e PRESSURE TO ITEM 44 Cms SWITCH 4 ON PILOT Du 44 TO ITEM 44 N ON PILOT SHUT OFF 7 PRESSURE TEST PORT INCLUDES
7. This heater is a category Ill appliance when horizontally vented through a wall using the supplied sidewall vent terminal All national and local codes pertaining to the installation of such venting systems must be followed Horizontal 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 A CAUTION 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 Termination of a sidewall vent system with a device other than the supplied vent hood could affect system performance and result in a safety hazard IMPORTANT Plan the layout of the vent system backward from the vent termination to the water heater 1 Use the layout of the vent system backward from the vent termination to the water heater BEWARE OF CONCEALED WIRING AND PIPING INSIDE OF WALL REFER TO TABLE 5 FOR THE MAXIMUM WALL THICKNESS B FOR EACH MODEL 2 Slide hood through opening from outside Fasten hood to exterior wall with anchors and screws supplied 3 Install covers plate and fasten to inside wall with 4 screws 4 Attach a seal ring Meltalbestos SR or equivalent to the vent hood collar
8. Jacket 195046 195046 Valve Relief Thermostat W E C O Cover Front Valve Drain Jacket Base GPV Vent Kit 192049 1 includes the following items 2 pieces of hood required for direct vent 9A Hood Vent Side Wall 191235 191235 Reducer Flue 191981 191981 Burner Assembly 196795 2 196795 1 Cleanout Assembly includes the following items 11 Cleanout Cover 11B Gasket Screw Thread Rolling Items not illustrated 3t Quantities if more than one shown in parenthesis next to part number Part numbers underlined are recommended stock items for emergency replacement GPG 740A 83523 48 4 192828 181260 26273 6 69852 1 170777 5 GPV 740A 83523 48 4 194974 16 195046 99465 3 192828 GPG BURNER ASSEMBLY Part numbers are listed on page 37 TO ITEM 43 AN TO ITEM 42 1 ON PILOT VALVE ON LOW GAS TO ITEM 43 gt ON PILOT SHUT OFF ORIFICE 26 INCLUDES 8 9 amp 10 ITEM 43 ON TEE ON PILOT REGULATOR 36 Item PART LIST FOR BURNER see drawing on page 36 Description GPG 540A GPG 650A Ignition Control Motor 1 4 HP 3450 RPM Valve 24 60 Gas Valve Air Switch Transformer 120 24 Low Gas Pressure Switch Flame Rod Igniter Thermostat Regulator 3 8 Grounding Lug Std Hardware Purchase Locally Tubing 3 8 X 1 4 Brass Reducer 3 8 X 1 4 Brass Tee 1 4
9. ir VALVE OPENING L One 11 2 INLET OPENING FRONT amp H A NY B m Az CLEANOUT o OPENING ALL DIMENSIONS IN INCHES MILLIMETERS c Conn HORIZONTAL amp DIRECT VENTING GPV MODELS MAXIMUM TOTAL 75 EQUIVALENT FEET INTAKE AND EXHAUST ALLOWED FLUE REDUCER TO BE HIPPED W VENT HOOD 11 2 NPT OUTLET OPENING FRONT amp BACK 1 NPTT amp P VALVE OPENING 11 2 NPT INLET OPENING FRONT amp BACK CLEANOUT OPENING Approx Ship Wt GPG GPV 8034 73 13214 9 6 261 2 29 1 2 48 1 2 2 051 1 854 2 362 1 232 431 kg 540 GPG GPV 8034 73 3214 9 8 261 2 291 2 48 1 2 650 2 051 1 854 2 362 1 232 431 kg GPG GPV 8034 73 3214 9 8 261 72 29 1 2 48 1 2 740A Minimum gas supply pipe is 1 1 4 reference Table 7 for gas supply pipe size Storage Capacity U S Gals Litres Input Rating BTU HR Nat Recovery Rating 100 F Rise Current Draw 120V 60Hz 1 Phase Recovery Rating GPH 140 F Rise GPH GPG GPV 540A 85 261 540 000 523 6 GPG GPV 650A 85 261 650 000 GPG GPV 740A 85 261 740 000 718 512 6 0 Amps Based on 80 thermal efficiency obtained in State engineering laboratories NOTE To compensate
10. or burner See Table 5 limitations on venting system design for direct vent installations TABLE 5 Inches mm Flue Outlet Dia Flue Reducer Dimension Supplied Min Exhaust Vent Dia Inch mm Min Intake Vent Dia Inch mm GPV 540A 740A 9 229 9x8 229 x 203 8 203 8 203 Maximum Number Of Elbows Intake Maximum Number Of Elbows Exhaust Total Intake Vent Length Equiv Ft Total Exhaust Vent Length Equiv Ft Note Barometric draft control is not used in direct vent installations as the venting system must be sealed When calculating the equivalent length of a venting system each 90 elbow is equivalent to 10 feet of straight pipe Each 45 elbow is equivalent to 5 feet 1 5 m of straight pipe Do not exceed the maximum number of elbows as shown in Table 5 In no case may the sum of the straight pipe lengths and the equivalent lengths of the elbows exceed the valves in Table 5 VENT TERMINAL LOCATIONS EXHAUST See Horizontal Venting in this manual for acceptable locations for exhaust hoods VENT TERMINAL LOCATIONS INTAKE When considering locations for the intake terminal bear in mind that the terminal 9 Shall be located not less than 12 304 8 mm above grade 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 Shall not be located directly above an exhaust
11. 3 4 1 1174 11 2 2 212 3 10 175 1400 2100 3960 6300 11000 23000 20 120 250 485 950 1460 2750 4360 7700 15800 _ 97 200 375 770 1180 2200 3520 6250 12800 82 170 320 660 990 1900 3000 5300 10900 50 73 151 285 580 900 1680 2650 4750 9700 60 66 138 260 530 810 1520 2400 4300 8800 80 57 118 220 460 690 1300 2050 3700 7500 90 53 110 205 430 650 1220 1950 3450 7200 100 50 103 195 400 620 1150 1850 3250 6700 125 44 93 175 360 550 1020 1650 2950 6000 150 40 160 325 500 950 1500 2650 5500 7209 72 155 280 1280 2280 4600 TABLE 9A MAXIMUM CAPACITY 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 IN Nominal Iron Pipe Sizes Millimeters METERS 1 2 3 4 1 11 4 7 11 277 2 21 2 3 4 30 51 105 199 410 615 1160 1845 3221 6735 61 35 7 142 278 428 805 1277 2255 4626 934 28 59 110 225 346 644 1031 1830 3748 122 24 50 94 193 290 556 878 1552 3192 152 21 44 170 264 492 776 1391 2840 183 19 40 76 155 237 44
12. 6207 54 Rocker Switch 6207 46 6207 46 O Ring Seal Plastic Cap SC 1 1 Pipe IS2 Air Switch 0 3 Blocked Flue 152 Air Switch 0 9 Blower Proof 171080 IS2 Air Switch 0 3 Air Intake 171070 171070 NPM Panel Bracket K10304 K10304 GPV 740A 6207 14 6207 15 6207 47 6207 17 6207 19 6207 20 6207 25 6207 26 6207 43 6207 53 6207 54 6207 46 171080 171070 K10304 STATE WATER HEATERS 500 Lindahl Parkway Ashland City TN 37015 Phone 1 800 821 2017 Fax 1 800 6449306 website www statewaterheaters com WATER HEATERS 500 Lindahl Parkway Ashland City TN 37015 Phone 800 821 2017 Fax 800 644 9306 www statewaterheaters com
13. CHECK VALVE MUST BE IDENTICAL HEATERS re ar B Ar Us c cafa RETURN LINE FROM 180 F 82 2 C WATER CIRCULATING LOOP IF USED 15 TWO TEMPERATURE THREE HEATERS TWO PRE HEATERS ONE BOOSTER WITH OR WITHOUT BUILDING RECIRCULATION HOT WATER TO FIXTURES THERMOMETER THERMOMETER lt 4 PREHEATED WATER TO BOOSTER ADD CHECK VALVE WHEN CIRCULATING LOOP IS USED CIRCULATING THERMOMETER HH PUMP eon fle u 180 F 82 2 C i ED WATER OUTLET VALVE PLUG COCK ALL MANIFOLDING MUST BE EQUAL LENGTH TYPICAL BOOSTER LINE TEMP LINE TEMP HEATER CONTROL CONTROL COLD WATER SUPPLY 95 SEE INSERT m RETURN LINE FROM 180 F CIRCULATING LOOP IF USED A 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 CAUTION 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 FOR MULTIPLE HEATER INSTALLATION SEE MANIFOLD KIT SPECIFICATIONS PAGE 18 TWO TEMPERATURE TWO HEATERS ONE PRE HEATER ONE BOOSTER HEATER WITH OR WITHOUT BUILDING RECIRCULATION HOT WATER
14. FLAMMABLE VAPORS AND 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 27 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 MAINTENANCE SCHEDULE Following are the instructions for performing some of the recommended maintenance Power burner inspection and adjustment should be performed by a competent technician MAINTENANCE SCHEDULE Lime Scale UN LIME Removal Semi Annually Delimer Relief Valve Inspect Semi Annually non detergent Oiling Four Months motor oil As Required Soft Brush no spillage Inspect Every 3 Months into room Joints should be sealed Sediment Removal SAE No 20 Circulating Pump 1 Clean Inlet Screen and Blower Wheel Power Burner Blower Power Burner and Ignition Device 2 Make sure gate Barometric Damper swings freely Every 3 Vent System Inspect Months 1 2 If furnished with oiling provisions If flange gasket is damaged it must be replaced ELECTRICAL SERVICING A CAUTION LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION VERIFY PROPER OPERATION AFTER SERVICING FLUSHING 1 Turn off the heater
15. NOT THREAD OR CAP THE END OF THIS LINE RESTRICTED OR BLOCKED DISCHARGE WILL DEFECT THE PURPOSE OF THE VALVE AND IS UNSAFE DISCHARGE LINE SHALL BE INSTALLED TO ALLOW COMPLETE DRAINAGE OF BOTH THE VALVE AND LINE INSTALLATION DIAGRAMS ONE TEMPERATURE ONE HEATER VERTICAL STORAGE TANK FORCED CIRCULATION WITH OR WITHOUT BUILDING RECIRCULATION HOT WATER OUTLET 1 1 2 38 1 mm 3 4 NPT ALL BRONZE CIRCULATING STORAGE TANK HEATER 11 2 38 1 mm COLD WATER SUPPLY SEE INSERT A CHECK VALVE NOTE WHEN USING A State T 140 200 350 OR 400 STORAGE TANK USE LOWER 3 4 OPENING FOR TANK TEMP CONTROL T amp P RELIEF VALVE TANK TEMPERATURE A DANGER 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 THERMOMETER NOTE CONNECT RETURN LINE FROM HOT WATER RECIRCULATING LOOP IF USED TO COLD WATER INLET LINE VACUUM RELIEF VALVE INSTALL LOCAL CODES CONTROL ONE TEMPERATURE ONE HEATER HORIZONTAL STORAGE TANK FORCED CIRCULATION WITH OR WITHOUT BUILDING RECIRCULATION RELIEF VALVE HOT WATER OUTLET T amp P RELIEF TANK STORAGE TANK CONTROL qc m QOL RETURN LINE FROM BUILDING CIRCULATING LOOP IF USED WITH STORAGE TAN
16. The usage of water softening equipment greatly reduces the hardness of the water However this equipment does not always remove all of the hardness lime For this reason it is recommended that a regular schedule for deliming be maintained The depth of lime build up should be measured periodically Heaters will have about 3 76 mm of lime build up when the level of lime has reached the bottom of the cleanout opening or about 1 of lime build up if it has reached the drain valve opening A schedule for deliming should be set up based on the amount of time it would take for a 1 25 4 mm build up of lime Example 1 Initial inspection shows 1 2 12 7 mm of lime accumulation Therefore the heater can be delimed once a year Example 2 Initial inspection shows 2 50 8 mm of lime accumulation Therefore the heater should be delimed every 3 months Sediment and lime scale removal may be accomplished through the cleanout opening furnished on the heater see FEATURES The heater must be drained See DRAINING before removing cleanout cover on tank To dissolve and remove the more stubborn mineral deposits State UN LIME Professional delimer should be used 28 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 re
17. electrical disconnect switch 2 Open the drain valve and allow water to flow until it runs clean 3 Close the drain valve when finished flushing 4 Turn on the heater electrical disconnect switch 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 drain valve 5 If the heater is being drained for an extended shutdown it is suggested the drain valve be left open this period Follow FILLING instructions when restoring hot water service SEDIMENT REMOVAL Waterborne impurities consist of the particles of soil and sand which settle out and form a layer of sediment on the bottom of the tank For convenience sediment removal and lime scale removal should be performed at the same time LIME SCALE REMOVAL The amount of calcium carbonate lime released from water is in direct proportion to water temperature and usage The higher the water temperature or water usage the more lime deposits are dropped out of the water This is the lime scale which forms in pipes heaters and on cooking utensils Lime accumulation not only reduces the life of the equipment but also reduces efficiency of the heater and increases fuel consumption
18. settings should be based on fire rate and flue gas 0 CO reading see Table 10 for normal 0 CO reading A WARNING Excessive gas line pressure drop and or burner manifold pressure too low may cause burner start operate with excessive noise 2 Cycle the burner ON and OFF several times to check its operation Make sure the gas line pressure is below 14 w c when burner is OFF If gas line pressure exceeds 14 w c when the burner is off the gas supply line size must be increased to correct this problem see Table 9 for gas pipe size Check the operation of the limiting and operating controls Check the vent system seams and joints and ensure that there is no discharge of flue products into the room For standard vertical vent systems check the barometric damper control to make sure it operates freely and there is no discharge of flue products into the room Check the input rate by clocking the gas meter ADJUSTMENT PROCEDURE FOR FIRE RATE LOW NOX AND HIGH ELEVATION Fine Tune An acceptable input rate is within 2 of the rated input for the model Should it be necessary to adjust the gas pressure to the burner and or air damper of the blower to obtain the full input rate these steps should be followed A WARNING Never set burner combustion too lean causing noisy operation or too rich causing combustion chamber premature failure see Table 10 for proper settings A WARNING Never set ai
19. terminal Shall be located 12 304 8 mm above the snow line in geographical areas where snow accumulates Shall be located not less than 7 feet 2 1 m above grade when adjacent to a public walkway Shall not be closer than 3 feet 9144 m from the inside corner of an L shaped structure Shall be located not less than 3 feet 9144 m horizontally or 3 feet 9144 m vertically from gas line meter or other gas supply entering a structure see Figure 6 FILL GROOVE INNER VEE BANDS SEAL RING FLUE REDUCER INCLUDED WITH EXHAUST HOOD 8 xX 6 SELKIRK 203 2 mm X 152 4 mm SLIP SLIP REDUCER Meee TE NOT SUPPLIED DR MODEL G VENT an Son 75 EQIUVALENT FEET 23 m INNER PIPE OUTER PIPE k USE P 600 HERE 7 ON OUTDOOR VERTICAL INSTALLATIONS SPACER OUTER CHANNEL BAND INNER VEE BAND NT SEALANT 1 4 6 35 mm DEEP IN INNER VEE BAND GROOVE FLANGED INNER JOINT FIGURE 7B INNER VEE BAND WITH HIGH TEMP SILICONE e CHANNEL BAND p SHEET METAL SCREW 4 8 203 mm INTAKE VENTING DIRECT VENT SYSTEM INSTALLATION 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 7 BEWARE OF CONCEALED WIRING AND PI
20. used with factory approved anode s installed 6 in its original installation location 7 in the United States its territories or possessions and Canada 8 sized in accordance with proper sizing techniques for commercial and or residential water heaters 9 bearing a rating plate which has not been altered defaced or removed except as required by the warrantor 10 operated with properly installed dirt leg 11 fired with the fuel for which it was factory built 12 fired at the factory rated input b Any accident to the water heater any misuse abuse including freezing or alteration of it any operation of it in a modified form or any attempt to repair tank leaks will void this warranty c This warranty is voided if a device as a backflow prevention device check valves etc is installed 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 SERVICE AND REPAIR EXPENSES Under the limited warranty the warrantor will provide only a replacement water heater or part thereof The owner is responsible for all other costs Such costs may include bat are not limited to a Labor charges for services removal repair or reinstallation of the water heater or any component part b Shipping delivery handling and administrative charges for fo
21. you have obtained a GPG GPV 540A 650A or 740A model with the intent to use it with Liquefied Petroleum LP gas STOP Immediately contact your dealer to obtain a correct model CHEMICAL VAPOR CORROSION A WARNING CORROSION OF THE FLUEWAYS AND VENT SYSTEM MAY OCCUR IF AIR FOR COMBUSTION CONTAINS CERTAIN CHEMICAL VAPORS SUCH CORROSION MAY RESULT IN FAILURE AND RISK OF ASPHYXIATION Spray can propellants cleaning solvents refrigerator and air conditioning refrigerants swimming pool chemicals calcium 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 outside sources The limited warranty is voided when failure of water heater is due to a corrosive atmosphere Refer to the limited warranty for complete terms and conditions IMPROPER COMBUSTION A WARNING ATTIC AND OR EXHAUST FANS OPERATING ON THE PREMISES WITH A WATER HEATER CAN RESULT IN CARBON MONOXIDE POISONING AND DEATH OPERATION OF THESE FANS CAN PRODUCE A NEGATIVE DRAFT IN THE AREA OF THE WATER HEATER PREVENTING THE PRODUCTS OF COMBUSTION FROM EXHAUSTING THROUGH THE CHIMNEY OR VENT PIPE The venting of the water heater should be inspected by a qualified service technician at the t
22. 0A 650A amp 740A S Maximum spacing between two guides or a support and a guide in either a vertical or horizontal direction F Maximum height above a guide or support for free standing system above a roof or parapet wall 11 Use an expansion joint between any two fixed points in the exhaust venting system wherever the expansion may exceed 1 4 Selkirk Metalbestos model PS and model G venting will expand by one inch per 100 F in gas temperature per 100 feet of vent length The expansion can be calculated by the following formula D 100 Expansion Vent length between Inches two fixed points feet If the expansion calculated is greater than 1 4 an expansion joint must be used between the two fixed points 12 Attach the flue reducer included in the exhaust vent hood package to the flue collar on the heater 13 Attach the flue reducer to the vent system using a seal ring Attach this ring to the venting using the inner vee bands as outlined in Steps 5 7 14 Attach 8 air intake connector to intake vent hood collar It may be necessary to use a slip slip coupling to fit the pipe to the intake vent hood 15 Attach 8 air intake connector back to the 6 burner air inlet with 8 x 6 reducer 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 b
23. 5 703 1259 2577 213 18 37 70 143 220 410 659 1142 2372 244 17 35 64 135 202 381 1083 2196 274 16 32 eo 126 190 357 571 1010 2108 305 15 so 57 17 182 337 542 952 1962 381 13 27 51 105 161 299 483 864 1757 533 n 23 42 135 249 401 77 1464 Csiro ro ar Tao e ss ors soo Laer A WARNING THE HEATER IS NOT INTENDED FOR OPERATION AT HIGHER THAN 14 3 5 kPa WATER COLUMN 1 2 POUND PER SQUARE INCH SUPPLY GAS PRESSURE HIGHER GAS PRESSURES REQUIRE SUPPLEMENTAL REDUCING SERVICE REGULATION EXPOSURE TO HIGHER GAS SUPPLY PRESSURE MAY CAUSE DAMAGE TO THE GAS CONTROLS WHICH COULD RESULT IN FIRE OR EXPLOSION IF OVERPRESSURE HAS OCCURRED SUCH AS THROUGH IMPROPER TESTING OF GAS LINES OR EMERGENCY MALFUNCTION OF THE SUPPLY SYSTEM THE GAS VALVEMUST BE CHECKED FOR SAFE OPERATION MAKE SURE THAT THE OUTSIDE VENTS ON THE SUPPLY REGULATORS AND THE SAFETY VENT VALVES ARE PROTECTED AGAINST BLOCKAGE THESE ARE PARTS OF THE GAS SUPPLY SYSTEM NOT THE HEATER VENT BLOCKAGE MAY OCCUR DURING ICE STORMS LENGTH ITIS IMPORTANT TO GUARD AGAINST GAS VALVE FOULING FROM CONTAMINANTS IN THE GAS WAYS SUCH FOULING MAY CAUSE IMPROPER OPERATION FIRE OR EXPLOSION IF COPPER SUPPLY LINES ARE USED THEY MUST BE INTERNALLY TINNED AND CERTIFIED FOR GAS SERVICE BEFORE ATTACHING THE GAS LINE BE SURE THAT ALL GAS PIPE I
24. 8 9 10 TO ITEM 44 ON TEE ON PILOT REGULATOR PART LIST FOR BURNER see drawing on page 38 Description GPV 540A GPV 650A Ignition Control Motor 1 4 HP 3450 RPM Valve 24 60 Gas Valve Thermodisk Relay Transformer 120 24 Low Gas Pressure Switch Flame Rod Igniter Thermostat Regulator 3 8 Grounding Lug Std Hardware Purchase Locally Tubing 3 8 X 1 4 6207 14 6207 14 Brass Reducer 3 8 X 1 4 6207 15 6207 15 Brass Tee 1 4 6207 47 6207 47 Brass Tube 1 4 X 1 8 6207 17 6207 17 Std Hardware Purchase Locally 2 Std Hardware Purchase Locally Std Hardware Purchase Locally Pipe Plug 1 1 4 Drilled amp Tapped 6207 18 Orifice Spring 6207 19 6207 19 Junction Box 6207 20 6207 20 Junction Box Cover Ball Valve 1 Pilot Ass y Includes Items 8 9 amp 10 Air Staging Band Frame Motor Plate 6207 25 6207 25 Damper Stop is 6207 26 6207 26 90 Degree Adapter Ass y Housing Ass y Back Mount Panel Ass y Premix Air Housing Wheel Panel Box Door Pie Damper Inner Plate Pie Damper Middle Plate Outer Pie Damper Air Intake Kit Amber Light Std Hardware Purchase Locally Flat Washers 3 8 Tubing to FP 90 70 42 1 4 X 1 8 El Fitting 1 4 X 1 8 Hex Nipple 1 4 Ball Valve Model 740 1 4 Std Hardware Purchase Locally Orifice Aluminum 1 1 4 Std Hardware Purchase Locally Conduit Clamp 6207 43 6207 43 Premix Diffuser Ass y 6207 53 6207 53 Pilot Tubing 3 6207 54
25. AIN ADEQUATE BOOSTER OUTPUT ADD AN ANTI SCALD VALVE FOR HOT WATER SUPPLIED TO 1 rn a um HOT WATER SYSTEM MUST BE 1 LINE TEMP PROVIDED 3 i 4 CONTROL Fe x WIRING DIAGRAM FOR TEMPERED WATER LOOP IF USED CIRCULATING PUMP WIRING DIAGRAM a POINTA FIXTURES Ti RETURN LINE FROM 180 F 82 2 C CIRCULATING PUMP CHECK VALVE OR WATER METER WITH PLUG CHECK Mm CHECK VALVE PROVISIONS FOR 1 1COCK VALVE THERMAL EXPANSION OF WATER IN THE WIRING DIAGRAM FOR 180 F LOOP IF USED 120V AC LINE TEMPERATURE TOGGLE SWITCH CONTROL 1 WITH RED PILOT LIGHT DISHWASHER L2 NEUTRAL TANK TEMPERATURE CONTROL t L1 CIRCULATING 120V AC PUMP CIRCULATING PUMP INSTALL THERMAL EXPANSION TANK IF CHECK VALVE OR PRESSURE REDUCING VALVE IS USED IN SUPPLY L2 NEUTRAL TWO TEMPERATURE TWO HEATERS HIGH TEMPERATURE WITH OR WITHOUT BUILDING RECIRCULATION 180 F 82 2 C WATER OUTLET THERMOMETER TEMPERED WATER OUTLET SEE NOTE THERMOMETER MIXING VALVE rd amp br RELIEF VALVE VACUUM RELIEF a VALVE 12 TO 15 INSTALL PER LOCAL CODES ALL MANIFOLDING MUST BE EQUAL LENGTH i HEATER HEATER ALL MANIFOLDING MUST BE EQUAL LENGTH TU SEE NOTE n ar N 11 Ut cs PLUG T i COCK CIRCULATING PUMP eh co Zus LINE TEMP CONTROL
26. ARRANTY FOR THE FOLLOWING REASONS 1 INSULATION BLANKETS COVER IMPORTANT OPERATING INSTRUCTIONS AND SAFETY LABELS 2 INSULATION BLANKETS CAN RESTRICT THE AIR FLOW NEEDED FOR PROPER OPERATION OF THE COMBUSTION SYSTEM AND COULD RESULT IN FIRE ASPHYXIATION SERIOUS PERSONAL INJURY OR DEATH A WARNING FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN SERIOUS PERSONAL INJURY OR DEATH HIGH ALTITUDE INSTALLATIONS Your State water heater has been designed to operate at altitudes below 2000 Ft 609 6 m for appliance installation locations with elevations above 2000 Ft 609 6 m special considerations need to be taken Adjustments for high altitude can only be made by a State authorized GPG GPV Start up Agent To ensure your water heater operates properly at high elevation a State authorized GPG GPV Start up Agent will readjust the air intake damper setting and the gas manifold pressure if required NOTE Some gas utility companies derate the heating value of the supplied gas at high elevation Your authorized start up agent must adjust for actual heating value of the gas at the time of start up FEATURES LOW EMISSION CONTROL Your State water heater has been designed to comply with standards established by California South Coast Air Quality Management District SCAQMD the most stringent emissions control agency in the nation To ensure compliance with SCAQMD Rule 1146 2 your heater is equipped with an internal recirculati
27. BES 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 UNDERSIZED OPENINGS WILL CAUSE AIR TO BE DRAWN INTO THE ROOM THROUGH THE CHIMNEY CAUSING POOR COMBUSTION SOOTING MAY RESULT IN SERIOUS DAMAGE TO THE HEATER AND RISK OF FIRE OR EXPLOSION UNCONFINED SPACE In buildings of conventional frame brick or stone construction unconfined spaces may provide adequate air for combustion and ventilation If the unconfined space is within a building of tight construction building using the following construction weather stripping heavy insulation caulking vapor barrier etc air for combustion and ventilation must be obtained from outdoors or spaces freely communicating with the outdoors The installation instructions for confined spaces in tightly constructed buildings must be followed to ensure adequate air supply CONFINED SPACE When drawing combustion and dilution air from inside a conventionally constructed building to a confined space such a space shall be provided with two permanent openings ONE IN OR WITHIN 12 INCHES 304 8 mm OF THE ENCLOSURE TOP AND ONE IN OR WITHIN 12 INCHES 304 8 mm OF THE ENCLOSURE BOTTOM Each opening shall have a free area of at least one square inch per 1000 Btuh of the total input of all appliances in the enclosure but not less than 100 square inches If the confined space is within a bu
28. E 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 CAUTION 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 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 TOGGLE SWITCH MUST BE CLOSED ON DURING THE RINSE OPERATION AND OPEN OFF WHEN DISHWASHER IS NOT OPERATING OR WHEN ON LONG STANDBY NOTE 2 INSTALLLINE TEMPERATURE CONTROL IN AN UNINSULATED TEE BEYOND THE DISHWASHING MACHINE TAKEOFF IN THE SANITIZING LOOP CONTROL SHOULD BE SET AT 185 F NOTE3 ADJUST PLUG COCK SO THE SANITIZING LOOP FLOW RATE DOES NOT CAUSE UNNECESSARY TURBULENCE IN THE TANK NOTE4 IF TEMPERED WATER IS RECIRCULATED RETURN LINE SHOULD BE CONNECTED AT POINT A 17 THERMOMETER tH WATER HAMMER Tr 12 804 8 mm ARRESTOR v 381 mm 2 t c DISHWASHING n Ta 4 P roe SS y 5 Z a Aw D EE AC VALVE MAKE THIS DISTANCE SEE NOTE 4 AS SHORT AS POSSIBLE m WATER TEMPERATURE IN up un CONTROL NOTE 2 3 4 75 TOGGLE SWITCH ALL BRONZE CHECK PLUG NOTE 1 CIRCULATING PUMP VALVE COCK m N
29. ED NOTE AUTHORIZED START UP IS REQUIRED UNCRATING The heater is shipped in standard form for vertical venting with a barometric draft control assembly in a separate carton Optional horizontal vent models are shipped with one 1 exhaust vent hood and one 1 flue reducer in a separate carton Optional direct vent models are shipped with two 2 vent hoods in separate cartons The exhaust vent hood carton contains one 1 exhaust vent hood and one 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 possible A WARNING THERE IS A RISK IN USING FUEL BURNING APPLIANCES SUCH AS GAS WATER HEATERS IN ROOMS GARAGES OR OTHER AREAS WHERE GASOLINE OTHER FLAMMABLE LIQUIDS OR ENGINE DRIVEN EQUIPMENT OR VEHICLES ARE STORED OPERATED OR REPAIRED FLAMMABLE VAPORS ARE HEAVY AND TRAVEL ALONG THE FLOOR AND MAY BE IGNITED BY THE HEATER S IGNITER OR MAIN BURNER FLAMES CAUSING FIRE OR EXPLOSION SOME LOCAL CODES PERMIT OPERATION OF GAS APPLIANCES IF INSTALLED 18 INCHES OR MORE ABOVE THEFLOOR THIS MAY REDUCE THE RISK IF LOCATION IN SUCH AN AREA CANNOT BE AVOIDED THE HEATER SHALL BE LOCATED OR PRO
30. ENSIONS aa ente aa 2 FOREWORD 2 3 TABLE OF CONTENTS inii e tt er te ere ic etnies 3 GENERAL SAFETY INFORMATION Precautions nnne cud Liquid Petroleum Models 1 3 Chemical Vapor Corrosion E Improper Combustion 2 4 EXTENDED NON USE PERIODS 4 Cathodic Protection 4 Insulation Blankets 4 High Altitude Installations 4 4 Low EmmMission Control 4 High Limit Switch E C O 4 5 Dishwashing Machine Requirement 5 INSTALLATION INSTRUCTIONS 2 9 Required Ability D Uncrating m Locating the Heater 5 6 Hard W ler 6 Clearances 6 Air Requirements tener etr 6 Mt eere 6 7 Vertical Venting For GPG Models 7 Horizontal Side wall Venting For Models 7 8 Direct Venting For Models 9 11 Gas PIPING nennen nee ee 11 12 Gas Meter Si26 c otii brote Ed en eres 12 Gas Pressure 22 4 4
31. G FIGURE 2 HARD WATER Where hard water conditions exist water softening or the threshold type of water treatment is recommended This will protect the dishwasher Coffee urns water heaters water piping and other equipment See MAINTENANCE section for details of tank cleanout procedure CLEARANCES These heaters are designed for installation on non combustible flooring in an alcove with clearances to combustible construction of 6 152 4 mm from the sides and rear 24 610 mm from the top with a 6 152 4 mm minimum between vent pipe and ceiling Minimum clearance from flue pipe to combustible material is 6 152 4 mm see Figure 3 BAROMETRIC DRAFT CONTROL 610 mm PROPER INSTALLATION CLEARANCES FIGURE 3 A clearance of 30 762 mm shall be maintained from serviceable parts such as power burners relief valves flue baffles thermostats or drain valves AIR REQUIREMENTS KEEP APPLIANCE AREA CLEAR AND FREE OF COMBUSTIBLE MATERIALS GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS DO NOT OBSTRUCT THE FLOW OF COMBUSTION OR VENTILATING AIR A WARNING FOR SAFE OPERATION PROVIDE ADEQUATE AIR FOR COMBUSTION AND VENTILATION AN INSUFFICIENT SUPPLY OF AIR WILL CAUSE RECIRCULATION OF COMBUSTION PRODUCTS RESULTING IN AIR CONTAMINATION THAT MAY BE HAZARDOUS TO LIFE SUCH ACONDITION OFTEN WILL RESULT IN A YELLOW LUMINOUS BURNER FLAME CAUSING CARBONING OR SOOTING OF THE COMBUSTION CHAMBER BURNERS AND FLUE TU
32. K ABOVE HEATER PROVIDE HEAT TRAP TO APPROX MID POINT OF HEATER 38 1 mm PLUG HEATER 3 4 NPT 75 11 2 ALL BRONZE 38 1 mm CIRCULATING COLD WATER SUPPLY SEE INSERT A PIPE TO OPEN DRAIN INSTALL INACCORDANCE WITH LOCAL CODES 14 A 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 TEMPERATURE INSTALL THERMAL EXPANSION TANK IF CHECK VALVE OR PRESSURE REDUCING VALVE IS USED IN SUPPLY CIRCULATING PUMP WIRING DIAGRAM TANK TEMPERATURE CONTROL L1 CIRCULATING 120V AC PUMP L2 NEUTRAL TWO TEMPERATURE ONE HEATER HIGH TEMPERATURE WITH OR WITHOUT BUILDING RECIRCULATION 180 F 82 2 C WATER OUTLET THERMOMETER TEMPERED WATER OUTLET MIXING COLD WATER SUPPLY SEE INSERT A PIPE RELIEF VALVE TO OPEN DRAIN NOTE IF TEMPERED WATER 15 RECIRCULATED RETURN LINE SHOULD BE CONNECTED AT POINT A INSTALL IN ACCORDANCE WITH LOCAL CODES A DANGER TEMPERATURE SETTING SHOULD NOT EXCEED SAFE TEMPERATURE AT FIXTURES SEE WATER TEMPERATURE 12 304 8 mm TO 15 381 mm RELIEF CONTROL WARNING ON PAGE 23 IF VALVE HIGHER PREHEAT TEMPERATURES ARE HEATER NECESSARY TO OBT
33. L LOWNOX WATER HEATER FROM BAROMETRIC VENT IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THIS APPLIANCE REQUIRES REPLACEMENT IT MUST BE REPLACED WITH TYPE 105 C THERMOPLASTIC OR EQUIVALENT EXCEPT IN BURNER HOUSING USE 200 C WIRE FIGURE 11 20 LEGEND 120 VAC 1 PHASE 60 Hz Y YELLOW Y BK YELLOW BLACK G Y GREEN YELLOW W BK WHITE BLACK T TAN BK BLACK FUSED DISCONNECT BL BLUE W WHITE R RED OR ORANGE HEATER ON OFF HEATER PANEL SWITCH THERMOSTAT AIR SWITCH THERMAL RELAY o 2 gt FLAME ROD IGNITOR MAIN FUEL YELLOW MAIN GAS VALVE THERMAL CUT OFF SPARK F R SENSE 24V GND24V GND PV HONEYWELL 8680J1004 WIRING DIAGRAM FOR COMMERCIAL LOWNOX WATER HEATER FOR HORIZONTAL amp DIRECT VENT IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THIS APPLIANCE REQUIRES REPLACEMENT IT MUST BE REPLACED WITH TYPE 105 C THERMOPLASTIC OR EQUIVALENT EXCEPT IN BURNER HOUSING USE 200 C WIRE FIGURE 12 21 FOR YOUR SAFETY READ BEFORE LIGHTING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life BEFORE OPERATING ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROMALL LINES A This appliance is equipped with an ignition device which automatically lights the burner Do NOT try to light burner by hand BEFORE LIGHTING Smell all around the appliance area for gas Be sure t
34. LES FLAME OR OTHER SOURCES OF IGNITION FOR THIS PURPOSE GAS METER SIZE CITY GASES ONLY Be sure that the gas meter has sufficient capacity to supply the full rated gas input of the water heater as well as the requirements of all other gas fired equipment supplied by the meter If the gas meter is too small request the gas company to install a larger meter having adequate capacity GAS PRESSURE REGULATION Main line gas pressure to the water heater should be between 8 w c 2 kPa minimum dynamic pressure or net pressure and 14 3 5 kPa maximum w c static pressure The inlet gas pressure must not exceed the maximum value A service regulator is necessary if higher gas pressures are encountered see Table 10 Due to pressure drop along gas supply line to maintain 8 w c 2 kPa minimum dynamic pressure initial gas inlet pressure must be set at higher than 8 w c 2 kPa The gas regulator must be properly sized to prevent unstable control or excessive pressure drop GAS VALVES Figure 10 shows the gas control valve that is supplied on these heaters REGULATOR ADJUSTMENT COVER SCREW GAS VALVE TOP KNOB INLET Pe GAS OUTLET MANIFOLD PRESSURE TAP TH amp TR MAIN VALVE TERMINALS GAS INLET D D SOLENOID VALVE ROBERTSHAW 7000 DERHC GAS CONTROL VALVE FIGURE 10 WATER LINE CONNECTIONS Following are detailed installation diagrams for typical methods of application for the water heaters Th
35. LOSS OR DAMAGE TO PERSONAL PROPERTY OR OTHER CONSEQUENTIAL DAMAGE THE WARRANTOR SHALL NOT A LIABLE BY VIRTUE OF THIS WARRANTY OR OTHERWISE FOR DAMAGE TO ANY PERSONS OR PROPERTY WHETHER DIRECT OR INDIRECT AND WHETHER ARISING IN CONTRACT OR IN TORT Fill in the warranty for your own reference Keep it Registration is not a condition of warranty The model and serial number are found on the heater s rating plate Model No Serial No Date Installed Dealers Name Dealer s Address Phone No City and State Zip KEEP THIS WARRANTY POSTED ADJACENT TO THE HEATER FOR FUTURE REFERENCE 33 state COMMERCIAL TANK TYPE WATER HEATER REPLACEMENT PARTS LIST ea 3 MODELS GPG GPV 540A THRU 740A RELIEF VALVE Part numbers are listed on page 35 SERIES 104 BAROMETRIC DRAFT CONTROL STATE WATER HEATERS 500 Lindahl Parkway Ashland City TN 37015 Phone 1 800 821 2017 Fax 1 800 6449306 website www statewaterheaters com PART LIST FOR PAGE 34 Description GPG 540A GPG 650A Anode Plug 183523 48 4 Baffle Flue 194974 16 Cover Jacket 192828 Cover Front 181260 Valve Drain h Jacket Base 195045 Burner Assembly Cleanout Assembly includes the following items 11A Cleanout Cover 11B Gasket Screw Thread Rolling Barometric Draft Control Item Description Anode Plug 183523 48 4 183523 48 4 Baffle Flue 194974 16 194974 16 Cover
36. MODELS GPG GPV 540A 650A AND 740A COMMERCIAL GAS GLASS LINED TANK TYPE LOW NOx WATER HEATER e INSTALLATION OPERATION MAINTENANCE LIMITED WARRANTY 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 DOIF YOU SMELL GAS e Donottry tolightany appliance e Do not touch any electrical switch do notuse any phone in your building e Immediately call your gas supplier A caution from a neighbor s phone Follow the rExrINBLACK BOLD TYPE OR UNDERLINED gas supplier s instructions CONTAINS INFORMATION RELATIVE TO YOUR SAFETY PLEASE READ THOROUGHLY BEFORE e If you cannot reach your gas supplier INSTALLING AND USING THIS APPLIANCE call the fire department Installation and service must be Ostate performed by a qualified installer service agency or the gas supplier Rh www statewaterheaters com PLACE THESE INSTRUCTIONS ADJACENT TO HEATER AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE PRINTED IN U S A 1004 PART NO 195047 000 ROUGH IN DIMENSIONS STANDARD BAROMETRIC DRAFT CONTROL GPG MODELS 112 21 12 INLET OUTLET amp DIP TUBE o 11 2 NPT OUTLET OPENING FRONT amp BACK SA 1 NPTT amp P
37. N TO USE A HOT WATER TAP OR TO DRAW THEIR OWN BATH WATER NEVER LEAVE A CHILD OR DISABLED PERSON UNATTENDED INA BATHTUB OR SHOWER THE WATER HEATER SHOULD BE LOCATED INAN AREA WHERE THE GENERAL PUBLIC DOES NOT HAVE ACCESS TO SET TEMPERATURES SETTING THE WATER HEATER TEMPERATURE AT 120 F 49 C WILL REDUCE THE RISK OF SCALDS Some states or provinces require settings at specific lower temperatures Below you will find listed the approximate time to burn relationship for normal adult skin Short repeated heating cycles caused by small hot water uses can cause temperatures at the point of use to exceed the thermostat setting by up to 20F If you experience this type of use you should consider using lower temperature settings to reduce scald hazards Time to Produce 2nd amp 3rd Degree Burns on Adult Skin Nearly instantaneous Nearly instantaneous About 1 2 second About 1 1 2 seconds Less than 5 seconds About 30 seconds More than 5 minutes Temperature Setting 180 F 82 C 170 F 77 C 160 F 71 C 150 F 66 C 140 F 60 C 130 F 54 C 120 F 49 C Valves for reducing point of use temperature by mixing cold and hot water are available Also available are inexpensive devices that attach to faucets to limit hot water temperatures Contact a licensed plumber or the local plumbing authority The water temperature is controlled by athermostat fig 2 which has two sensing ele
38. OTE 3 Uu VACUUM RELIEF VALVE INSTALL PER LOCAL CODES INSTALL THERMAL EXPANSION TANK IF CHECK VALVE OR PRESSURE REDUCING VALVE IS USED IN SUPPLY WIRING DIAGRAM FOR 180 F LOOP IF USED 120V AC Lo LINE NEUTRAL DISHWASHER TEMPERATURE L1 TOGGLE SWITCH CONTROL WITH RED PILOT LIGHT CIRCULATING PUMP 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 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 A WARNING FAILURE TO PROPERLY MANIFOLD MULTIPLE WATER HEATERS AND PROVIDE ADEQUATE STORAGE CAPACITY IN ACCORDANCE WITH PROPER SIZING TECHNIQUES CAN RESULT INIMPROPER OPERATION AND POSSIBLE FIRE RESULTING IN PROPERTY DAMAGE PERSONAL INJURY OR DEATH HEATERS SHOULD BE MANIFOLDED IN PARALLEL FOR UNIFORM HYDRONIC LOADING PER THE DIAGRAMS SHOWN 82 2 083 mm 1 524 mm IN THIS MANUAL T THREE UNIT MANIFOLD KIT m s PART NO 195703 __ 2 1 2 NPT INLET AND OUTLET 82 MANIFOLD CONNECTIONS 2 083 mm i TE k CS 6 152 mm NR TY
39. PICAL 1 524 mm Ya m lt 82 2 083 FOUR UNIT MANIFOLD KIT PART NO 195704 2 1 2 NPT AND OUTLET MANIFOLD CONNECTIONS 18 60 TWO UNIT MANIFOLD PART NO 195702 N 1 1 2 NPT INLET AND OUTLET MANIFOLD CONNECTIONS 6 152 mm TYPICAL gt b 1 0 152 TYPICAL 3 505 mm HEATER 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 EQUIVALENT EXCEPT IN THE BURNER HOUSING USE 200 C WIRE The power burner is wired to the heater as shown in Figure 11 for GPG models and Figure 12 for GPV models The model and rating plate provided the electrical information needed to size the complete heater branch supply All electrical work must be installed in accordance with the National Electrical Code and local requirements When installed the appliance must be electrically grounded in accordance with local codes or in the absence of local codes with the National Electrical Code ANSI NFPA 70 1987 DO NOT ENERGIZE THE BRANCH CIRCUIT BEFORE THE HEATER TANK IS FILLED WITH WATER START UP IMPORTANT AUTHORIZED START UP REQUIRED Start up by a State Authorized GPG GPV Start Up Agent is required on the model covered by this manual Start up and Operation of this unit by other than an Authorized GPG GPV Start Up Agent wil
40. PING INSIDE WALL REFER TO TABLE 3 FOR THE MAXIMUM WALL THICKNESS B FOR EACH MODEL Slide hoods through openings from outside Fasten hoods to exterior wall with anchors and screws supplied Install cover plate and fasten to inside wall with 4 screws Attach a seal ring Selkirk Metalbestos Model SR or equivalent to the vent hood collar see Figure 7 INNER VEE BAND OUTER MAXIMUM 75 EQUIVALENT FEET FOR DIRECT AND HORIZONTAL VENT CUT HOLE THROUGH WALL 1 2 LARGER THAN VENT HOOD TO SR FACILITATE EASE OF SEAL RING ASSEMBLY WASHER 4 EXPANDING FASTNER 4 N N 3 FEET MIN 9144m SHEET METAL SCREW 4 lt FIGURE 7 10 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 tighten the screws securing the bands 8 Align the outer channel band with the outer pipe grooves and tighten the screws securing the bands 9 Repeat steps 6 8 for each successive pipe length until the venting reaches the heater 10 Follow the manufacturer s instructions for proper support and guide spacing for horizontal runs of pipe see Table 6 TABLE 6 Vent Diameter Aw es 8 GPV 54
41. S The heater is equipped with a double acting barometric draft control as shown in Figure 15 The damper gate must pivot freely in the ring guides 29 WEIGHT COUNTER WEIGHT FIGURE 15 To test gate for operation gently tap gate and observe DO NOT OIL Adjust the number of counter weight washers on the control to maintain a negative draft of 0 02 to 0 04 w c in the venting See VERTICAL VENTING page 8 NOTE THAT THIS CONTROL WILL ONLY BE PRESENT IN A VERTICAL VENT INSTALLATION VENT SYSTEM Examine the vent system every 3 months Points of inspection are as follows 1 Check for obstructions and or deterioration of vent piping and vent hood Replace immediately where needed Vent pipe and vent hood screen should be cleaned of foreign material and soot The screen is located inside the vent hood outlet and is accessible from the outside of the hood Do not reach inside the vent when the heater is in operation Check all vent system connections for leakage and re seal as required using Hi Temp Silicone sealer or equivalent CHECKLIST AND SERVICE INFORMATION IMPORTANT The installer may be able to observe and correct certain problems which might arise when the unit is put into operation or when it is re fired after a prolonged shutdown HOWEVER it is recommended that only qualified servicemen using appropriate test equipment be allowed to service the heater BE SURE TO TURN OFF THE ELECTRICIT
42. S CLEAN ON THE INSIDE TO TRAP ANY DIRT OR FOREIGN MATERIAL IN THE GAS SUPPLY LINE A DIRT LEG SOMETIMES CALLED A SEDIMENT TRAP OR DRIP LEG MUST BE INCORPORATED IN THE PIPING SEE FIG 10 THE DIRT LEG MUST BE READILY ACCESSIBLE AND 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 compound to the first two threads Use compounds resistant to the action of liquefied petroleum gases DISCONNECT THE APPLIANCE AND ITS MANUAL GAS SHUT OFF VALVE FROM THE GAS SUPPLY PIPING SYSTEM DURING 12 ANY SUPPLY PRESSURE TESTING EXCEEDING 1 2 PSIG GAS SUPPLY LINE MUST BE CAPPED WHEN DISCONNECTED FROM THE HEATER FOR TEST PRESSURES OF PSIG OR LESS THE APPLIANCE NEED NOT BE DISCONNECTED BUT MUST BE ISOLATED FROM THE SUPPLY PRESSURE TEST BY CLOSING THE MANUAL GAS SHUT OFF VALVE REGULATED GAS 4 MINIMUM 1 1 4 GAS PIPE REQUIRED SUPPLY LINE PIPE CAP GAS SUPPLY LINE REDUCER GAS PIPING AND DIRT LEG INSTALLATION FIGURE 9 BEFORE PLACING THE HEATER IN OPERATION CHECK FOR GAS LEAKAGE USE SOAP AND WATER SOLUTION OR OTHER MATERIAL ACCEPTABLE FOR THE PURPOSE IN LOCATING GAS LEAKS DO NOT USE MATCHES CAND
43. SOURCES OF IGNITION MUST BE INACTIVATED OR REMOVED The following test equipment should be on hand all test equipment must be acclimated to ambient temperature before calibration and use CO indicator Fyrite or similar or O analyzer CO indicator Monoxor or similar Stack thermometer Draft Gauge or inlined manometer Two U Tube manometers or calibrated 0 10 and 0 35 w c pressure gauges Combination volt ammeter 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 Check voltage at disconnect switch to make certain that it matches that shown on the burner label Apply a few drops of No 20 SAE non detergent oil to motor bearings Drill max 5 16 hole in breeching as close as possible to flue connection on heater to install stack thermometer and combustion analyzing equipment see Figure 4 You are now ready to begin the burner start up procedure LEGEND Y YELLOW Y BK YELLOW BLACK G Y GREEN YELLOW W BK WHITE BLACK T TAN BK BLACK FUSED DISCONNECT BL BLUE W WHITE R RED HEATER ON OFF OR ORANGE SWITCH 120 VAC 1 PHASE 60 Hz HEATER PANEL THERMOSTAT BLACK NOIR qd AIR DIFF SWITCH o d E gt FLAME ROD IGNITOR MAIN FUEL YELLOW MAIN GAS VALVE THERMAL CUT OFF LOW GAS SWITCH SPARK X FR SENSE 24V GND24V GND PV HONEYWELL 8680J1004 WIRING DIAGRAM FOR COMMERCIA
44. SSING OUT OF THE VALVE DURING THIS CHECKING OPERATION If the temperature and pressure relief valve on the heater discharges periodically or continuously it may be due to thermal expansion of water in a closed water supply system or it may be due to faulty relief valve Thermal expansion is the normal response of water when it is heated In a closed system thermal expansion will cause the system pressure to build until the relief valve actuation pressure is equaled Then the relief valve will open allowing some water to escape slightly lowering the pressure Contact your water supplier or local plumbing inspector on how to control this situation Two common corrections are listed in the CHECKLIST AND SERVICE INFORMATION that appears later in this manual ABOVE ALL DO NOT PLUG THE TEMPERATURE AND PRESSURE RELIEF VALVE THIS IS NOT A SOLUTION AND CAN CREATE A HAZARDOUS SITUATION CIRCULATING 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 CLEAR AND FREE OF COMBUSTIBLE MATERIALS GASOLINE OR OTHER FLAMMABLE LIQUIDS OR VAPORS DO NOT OBSTRUCT BURNER AIR OPENINGS OR VENTILATION GRILLES FOR COMBUSTION AIR REMOVE LINT ACCUMULATION FROMAIR INTAKE GRILL The main burner flame should be visually checked once a year for proper operation This can be observed through the peep
45. TECTED SO IT IS NOT SUBJECT TO PHYSICAL DAMAGE BY A MOVING VEHICLE A WARNING FLAMMABLE ITEMS PRESSURIZED CONTAINERS OR ANY OTHER POTENTIAL FIRE HAZARDOUS ARTICLES MUST NEVER BE PLACED ON OR ADJACENT TO THE HEATER OPEN CONTAINERS OF FLAMMABLE MATERIAL SHOULD NOT BE STORED OR USED IN THE SAME ROOM WITH THE HEATER THE HEATER MUST NOT BE LOCATED IN AN AREA WHERE IT WILL BE SUBJECT TO FREEZING LOCATE IT NEARAFLOOR DRAIN THE HEATER SHOULD BE LOCATED IN AN AREA WHERE LEAKAGE FROM THE HEATER OR CONNECTIONS WILL NOT RESULT IN DAMAGE TO THE ADJACENT AREA OR TO LOWER FLOORS OF THE STRUCTURE WHEN SUCH LOCATIONS CANNOT BE AVOIDED A SUITABLE DRAIN PAN SHOULD BE INSTALLED UNDER THE HEATER Such pans should be fabricated with sides at least 2 50 8 mm deep with length and width at least 2 50 8 mm greater than the diameter of the heater and must be piped to an adequate drain THE PAN MUST NOT RESTRICT COMBUSTION AIRFLOW Water heater life depends upon water quality water pressure and the environment in which the water heater is installed Water heaters are sometimes installed in locations where leakage may result in property damage even with the use of a drain pan piped to a drain However unanticipated damage can be reduced or prevented by a leak detector or water shut off device used in conjunction with a piped drain pan These devices are available from some plumbing supply wholesalers and retailers and detect and react to leakage
46. TO FIXTURES _ VACUUM RELIEF TEP VALVE THERMOMETER AIVE INSTALL PER LOCAL CODES OUTLET INSTALL THERMAL EXPANSION BOOSTED TEMPERATURE TANK IF CHECK VALVE OR PRESSURE REDUCING VALVE IS USED IN SUPPLY PRE HEATER WIRING DIAGRAM FOR 180 F LOOP IF USED 120V AC L2 LINE NEUTRAL DISHWASHER TEMPERATURE TOGGLE SWITCH CONTROL WITH RED TRP PILOT LIGHT RELIEF VALVE MAX 1 1 2 38 1 mm COLD WATER SUPPLY SEE INSERT A TYPICAL BOOSTER HEATER CIRCULATING PUMP PRE HEATED WATER TO 112 BOOSTER 38 1 mm CIRCULATING PUMP WIRING DIAGRAM PIPERELIEF VALVE TO OPEN DRAIN CONNECT CIRCULATING LINE FROM FIXTURES IF TANK TEMBEHATURE CONTHOL USED TO COLD WATER SUPPLY LINE OF PRE 140 F TO 150 F SHOULD BE MAXIMUM HEATER WATER TEMPERATURE MAINTAINED IN THE L1 PRESSEN CONNECT CIRCULATING LINEOF 180 FORBOOSTED 120vac CIRCULATING 120 F SHOULD BE THE Minimum WATER IFUSED TO INLET WATERLINE TO BOOSTER T TEMPERATURE OF WATER IN THE PRE NEUTRAL HEATERS INSTALL IN ACCORDANCE WITH LOCAL CODES 16 TWO TEMPERATURE ONE HEATER HIGH TEMPERATURE WITH RECIRCULATION OF SANITIZING LOOP COLD WATER SUPPLY END OF CIRCULATING PEE INSERTA LOOP WITHIN 5 FEET IF DISHWASHER v TEMPERED WATER T amp P RELIEF VALVE THERMOMETER OUTLET NOTE 4 A DANGER TEMPERATURE SETTING SHOULD NOT EXCEED SAFE TEMPERATURE AT FIXTURES SE
47. Y WHENEVER POSSIBLE OR APPROPRIATE WHILE CHECKING EQUIPMENT BURNER OPERATIONAL PROBLEMS 1 Refer to TROUBLESHOOTING for comprehensive service information provided with both heater and burner manuals NOT ENOUGH OR NO HOT WATER 1 Be certain the electrical disconnect switch serving the water heater is in the ON position 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 warm colder water creates the effect of less hot water 5 Look for hot water wastage and leaking or open hot water faucets 6 Sediment or lime scale may be affecting water heater operation Refer to MAINTENANCE for details 7 Heater or burner may be dirty Clean all heater flue pipes and flue connector see MAINTENANCE Have burner properly cleaned and readjusted 8 Burner may not be firing at proper rate Check gas pressure 9 Burner fan wheel may be dirty Clean fan wheel with a soft brush 10 Reset button on high limit control Figure 1 has operated Press reset button WATER IS TOO HOT 1 Referto WATER TEMPERATURE CONTROL WATER HEATER MAKES SOUNDS 1 Sediment or lime scale accumulation cause rumbling and pounding noises when the heater
48. and burner exploded view see Figure 12 and the wiring diagram located on page 20 GHoneywell is a registered trademark of Honeywell International Inc and the troubleshooting section of burner manual before continuing Make sure the appliance is connected to a 120 Vac 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 Vac Also to verify correct polarity check for 120 Vac between black wire and G If there is no voltage check for a loose connection or open switch at the high limit or thermostat If there is 120 volts between black wire and white wire check for loose connections or a locked rotor If the rotor cannot be freed the motor and blower assembly must be replaced BURNER LOCKOUT ONCE IN A WHILE Under this condition the burner operates properly for days and burner lockout occurs once in a while The root causes for the burner occasional lockout include 1 Gas inlet pressure too low 2 Condensation over the ignitor area 3 the pilot flame is too weak to light the main flame reliably 4 the pilot air gas ratio is out of range causing pilot flame to be unreliable 1 Turn burner switch to OFF position and turn off the main gas valve Robertshaw 2 Install manometers for gas inlet pressure manifold pressure and pilot gas pressure se
49. 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 THE WATER HEATER THE RELIEF VALVE S MUST NOT BE REMOVED OR PLUGGED In addition to the appliance relief valve each remote storage tank that may be used in conjunction with this appliance shall also be installed with a properly sized rated and approved temperature ANSI and pressure ASME relief valve s This relief valve shall comply with the standard for relief valves and automatic gas shut off devices for hot water supply systems ANSI Z21 22 CSA 4 4 Your local code authority may have other specific relief valve requirements A WARNING THE PURPOSE OF A RELIEF VALVE IS TO AVOID EXCESSIVE PRESSURE OR TEMPERATURE INTO THE STEAM RANGE WHICH MAY CAUSE SCALDING AT FIXTURES TANK EXPLOSION AND SYSTEM OR HEATER DAMAGE NO VALVE IS TO BE PLACED BETWEEN THE RELIEF VALVE AND THE TANK ADRAIN LINE MUST BE CONNECTED TO THE RELIEF VALVE TO DIRECT DISCHARGE TO ASAFE LOCATION TO AVOID SCALDING OR WATER DAMAGE THIS LINE MUST NOT BE REDUCED FROM THE SIZE OF THE VALVE OUTLET AND MUST NOT CONTAIN VALVES RESTRICTIONS NOR SHOULD IT BE LOCATED IN FREEZING AREAS DO
50. commended for use on glass lined tanks State Form No 4800 entitled Why When and How describes tank cleaning methods and materials UN LIME and the booklet may be obtained through your State dealer or distributor The cleanout opening is shown in Figure 9 To clean heater through cleanout opening proceed as follows 1 Turn off water inlet valve the heater electrical disconnect switch and open drain valve Remove outer cover plate from lower side of heater jacket Remove cover from cleanout opening Remove lime scale or sediment using care not to damage the glass lining Inspect cleanout plate gasket if new gasket is required replace with State part no 99038 Install cleanout plate Be sure to draw plate up tight by tightening screws securely Close drain valve open water inlet line and turn on the burner electrical disconnect switch Check for water leakage Replace outer jacket cover plate RELIEF VALVE At least twice a year the temperature and pressure relief valve should be checked to ensure that it is in operating condition To check the relief valve lift the lever at the end of the valve several times The valve should seat properly and operate freely A CAUTION BEFORE MANUALLY OPERATING A RELIEF VALVE MAKE SURE THAT A DRAIN LINE HAS BEEN ATTACHED TO THE VALVE TO DIRECT THE DISCHARGE TOAN OPEN DRAIN FAILURE TO TAKE THIS PRECAUTION COULD MEAN CONTACT WITH EXTREMELY HOT WATER PA
51. connections and spark leakage call AOS service center for steps of spark leakage checking Following burner manual instructions to re install the pilot assembly Turn on the Robertshaw gas valve turn the burner switch to ON position Cycle the heater ON OFF several times to ensure the problem is solved MOTOR RUNS CONTINUOUSLY PREPURGE TIME ELAPSES BUT MAIN FLAME NOT ESTABLISHED BURNER LIGHT NEVER ON 1 When the heater is first installed gas line must be purged properly prior to start up This heater is equipped with a flame control module that only allows one trial for ignition for 15 seconds and locks out if no flame signal is detected For initial start up two or more resets may be required to ensure that all the air has been purged from the gas pilot line To reset the heater turn the burner power switch to OFF position for at least one minute then turn it back ON Check for gas supply line manual valves in ON position and line pressure Make sure the pilot manual gas cock nearby the main gas valve is fully open After the 45 seconds prepurge cycle the pilot gas valve mounted on the panel click sound should be heard If you hear the pilot gas energized proceed to Step 5 Check 24 Vac control circuit in the following systematic approach Check for 24V between 24V and GND of Honeywell Flame Control Module which is located inside the burner control panel If voltage is OK proceed to Step 5
52. d During downdrafts it acts as a pressure relief control to prevent the downdraft from blowing into the heater It also allows for makeup air to enter the chimney without being drawn through the heater In both cases the control prevents the heater performance from being adversely affected by conditions within the chimney The draft control assembly must be installed without alteration This assembly is factory adjusted for horizontal application only and must be attached to the heater as shown in Figure 4 The direction in which the outlet to the draft controls assembly faces is arbitrary The assembly must be fitted to the jacket cover such that it is plumb and level to the ground Fasten the draft control assembly to the top cover using sheet metal screws at three locations or more as required Damper or other obstructions must not be installed between the heater and the barometric draft control assembly Do not adjust settings on gate When installed the damper gate must pivot freely in the ring guides This gate will automatically adjust to regulate the chimney draft imposed on the heater VENT CONNECTIONS Vent connections must be made to an adequate stack or chimney Refer to the National Fuel Gas Code or to the vent pipe manufacturer s gas vent and chimney sizing table to properly design and size the venting system Refer to Table 1 for the vent pipe size required for installation to the barometric draft control assembly outl
53. e Figure 12 for the pressure ports location 3 Check for the gas inlet pressure reset the service regulator if required to get 9 w c 2 2 kPa 10 w c 2 4 kPa inlet pressure while the burner is in the OFF position 4 Turn the burner ON Take blower pressure at the pressure port during the purge cycle see Figure 12 for location Take the pilot gas pressure at the same pressure port during the ignition period following 45 seconds purge cycle The pilot gas pressure should be 0 6 0 9 w c higher than blower pressure if not adjust the pilot gas regulator during the ignition cycle see Figure 12 If burner lights on during the ignition cycle cycle the unit on off several times to ensure pilot system is reliable Turn off the burner then follow Step 6 5 Turn the burner OFF follow burner manual instructions to remove the pilot assembly also refer to Figure 12 in this manual and procedures to check pilot assembly Items to check for the pilot system include Check for condensation over ignitor area Check for the ignitor gap 1 8 3 16 Check for the thermal cutoff continuity by ohm meter replace it if the thermal cutoff is open Check for the low gas pressure switch by ohm meter while pilot gas pressure is 7 w c 1 7 kPa or higher 31 Check for the continuity between the flame rod and sensor connection at Honeywell flame control module by the ohm meter Check for ignitor wire
54. e sealed with high temp silicone sealant Dow Corning 736 or equivalent 11 A WARNING PRIMERS AND CEMENTS ARE EXTREMELY FLAMMABLE AND MUST NOT BE STORED OR USED NEAR HEAT OR OPEN FLAME ALLOW ADEQUATE CURING TIME BEFORE OPERATING HEATER DRAIN VALVE AND ACCESS PANELS The heaters are equipped with a 3 4 NPT drain valves mounted above and to the left of the burner An access panel is located above and to the right of the burner see Figure 8 This panel covers the cleanout opening in the tank which is sealed by a gasket and cover Another cleanout access panel is located towards the back of the heater CLEANOUT TANK ACCESS PANEL CLEANOUT OPENING CLEANOUT GASKET CLEANOUT COVER FIGURE 8 GAS PIPING Contact your local gas service company to ensure that adequate gas service is available and to review applicable installation codes for your area Size the main gas line in accordance with Table 9 and Minimum required gas supply pipe size is 1 1 4 The figures shown are for straight lengths of pipe at 0 5 in w c pressure drop which is considered normal for low pressure systems Note that fittings such as elbows and tees will add to the pipe pressure drop TABLE 9 MAXIMUM CAPACITY 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 IN Nominal Iron Pipe Sizes Inches FEET 1 2
55. e 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 the circulation may be either by gravity or by means of a circulating pump When a circulating pump is used it is important to note that the flow rate should be slow so that there will be a minimum of turbulence inside the heater If a water heater is installed in a closed water system contact the water supplier or local plumbing inspector on how to control this situation A CAUTION A closed system will exist if a check valve without bypass pressure reducing valve without bypass or a water meter without bypass is installed in the cold water line between the water heater and street main or well Excessive pressure may develop causing premature tank failure or intermittent relief valve operation This is not a warranty failure An expansion tank or a similar device may be required in the inlet supply line between the appliance and the meter or valve to compensate for the thermal expansion of water under supply pressure SYSTEM CONNECTIONS The system installation must conform to these instructions and Robertshaw is a registered trademark of the Robertshaw Controls Company Corporation 13 to the local code authority having jurisdiction requires that all heavy piping be supported Good practice THERMOMETERS Not supplied Thermometers should be obtained
56. er to the separate Power Burner Manual provided with this water heater THERMOSTAT It is suggested the thermostat be turned to the lowest setting which satisfies the hot water requirements of the system This helps minimize scale formation in the heater HIGH LIMIT The high limit not adjustable is factory set to cutout at 205 F 96 C The high limit switch must be manually reset by depressing the reset button on front of the control when water temperature drops to about 180 F 82 C GAS AND AIR SUPPLY SPECIFICATIONS TABLE 10 Model GPG GPV 540A GPG GPV 650A Min Dynamic Gas Supply Line Pressure Max Static Gas Supply Line Pressure GPG GPV 750A 8 w c 2 kPa When heater is ON 14 w c 3 5 kPa When heater is OFF 4 7 w c 1 1 kPa Ref 4 7 w c 1 1 kPa Ref 4 7w c 1 1 kPa Gas Manifold Pressure Gas Orifice Size 11 16 Dial Setting 4 4 5 Combustion Emissions Range Flue Gas O2 5 6 5 or CO2 reading 8 9 Note Flue gas excess O below 3 may cause combustion chamber premature failure flue gas excess O above 7 may cause rough operation or incomplete combustion Final manifold pressure settings should be based on flue O CO reading Note Air inlet damper setting needs to be adjusted at field for direct vent and or high elevation installations MAINTENANCE GENERAL KEEP APPLIANCE AREA CLEAR AND FREE FROM COMBUSTIBLE MATERIALS GASOLINE AND OTHER
57. et TABLE 1 __ FlueOutlet 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 A NEGATIVE DRAFT MUST BE MAINTAINED IN VENTING A negative draft of 0 02 to 0 04 w c Must be maintained in venting system Measure draft at the location illustrated in Figure 4 Adjust the control counter weights if necessary as shown in the MAINTENANCE portion of this manual Where an existing chimney or vent is to be used be sure that the chimney or vent has adequate capacity for the number and sizes of gas appliances being vented through it Inspect the chimney or vent and remove all soot or other obstructions which will retard free draft Vent connectors making horizontal runs must have a minimum upward slope toward the chimney or vent of 1 4 inch per foot Vent connector length should be kept as short as possible Be sure that the vent pipe does not extend beyond the inside wall of a chimney see Figure 4 TO CHIMNEY SLOPE UP 1 4 6 35 mm MIN PER FOOT OF HORIZONTAL CHIMNEY CONNECTOR BAROMETRIC DRAFT CONTROL ASSEMBLY RUN MAXIMUM VERTICAL PIPING MEASURE DRAFT AT THIS LOCATION FIGURE 4 In venting systems where a continuous or intermittent back positive draft is found to exist the cause must be determined and cor
58. for the effects of high altitude areas above 2000 feet recovery ratings should be reduced approximately 496 for every 1000 feet above sea level 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 this manual These diagrams will serve to provide the installer with a reference for the materials and methods of piping necessary It is highly essential that all water gas piping and wiring be installed as shown on the diagrams Particular attention should be given to the installation of thermometers at the locations indicated on the diagrams as these are necessary for checking the proper functioning of the heater THE HEATER IS DESIGNED TO OPERATE ONLY ON NATURAL GAS THESE HEATERS MUST NOT BE COMBUSTIBLE FLOORS INSTALLED ON In addition to these instructions the equipment shall be installed in accordance with those installation regulations in accordance with those installation regulations in force in the local area where the installation is to be made These shall be carefully followed all cases Authorities having jurisdiction should be consulted before installations are made TABLE OF CONTENTS PAGE ROUGH IN DIM
59. g HOT WATER ODOR On occasion hot water may develop a strong odor If this occurs drain the heater completely flush thoroughly and refill If the problem persists chlorinating of the heater and replacement of the factory installed magnesium anodes with aluminum anodes may correct the condition Occasionally water softener companies recommend removal of heater anodes for odor reasons A CAUTION Unauthorized removal of the anode s will void the warranty For further information contact your dealer TROUBLESHOOTING warnine 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 A VOLT OHM METER AND A MICRO AMMETER DO NOT ATTEMPT TO TROUBLESHOOT OR REPAIR STATE EQUIPMENT ALTERING THE IGNITION MODULE AND OR CONTROL BOX WIRING IN ANY WAY COULD RESULT IN INTERNAL DAMAGE TO THE MODULE CIRCUITS POSSIBLY ALTERING THE IGNITION SEQUENCE ALLOWING GAS VALVES TO OPEN BEFORE THE HOT SURFACE IGNITER IS UP TO IGNITION TEMPERATURE NOTE ANY BYPASS ORALTERATION OF THE UNITS SAFETIES WILL RESULT IN VOIDING THEAPPLIANCE WARRANT Y Before performing any troubleshooting familiarize yourself with the particular appliance State power burners are supplied with Honeywell ignition control systems and Robertshaw gas control valves see Figures 10 and 11 Refer to the SEQUENCE OF OPERATION
60. he setpoint too quick less than a second burner may still run with excessive gas valve ON OFF cycle you must turn off the unit immediately re adjust the gas line regulator and or install a larger gas supply line If the blower inlet and or intake hood or flue outlet hood is are blocked for any reason the safety switches will open which will de energize the flame control module The spark generator is off The flame module monitors pilot flame current Should the flame failure occur during the Heating Mode the unit will start again from purging cycle Thermostat is satisfied switch opens Power is interrupted to the flame control module and blower motor Gas valves are closed Heater is in Standby Mode Thermostat is satisfied switch opens Power is interrupted to burner turning off blower and ignition control module Solenoid and main gas valves are closed Insufficient blower pressure causes safety pressure switches to open WATER TEMPERATURE CONTROL DANGER 23 A DANGER THIS WATER HEATER IS EQUIPPED WITH AN ADJUSTABLE THERMOSTAT TO CONTROL WATER TEMPERATURE HOT WATER TEMPERATURES REQUIRED FOR AUTOMATIC DISHWASHER AND LAUNDRY USE CAN CAUSE SCALD BURNS RESULTING IN SERIOUS PERSONAL INJURY AND OR DEATH THE TEMPERATURE AT WHICH INJURY OCCURS VARIES WITH THE PERSON S AGE AND TIME OF EXPOSURE THE SLOWER RESPONSE TIME OF CHILDREN AGED OR DISABLED PERSONS INCREASES THE HAZARDS TO THEM NEVER ALLOW SMALL CHILDRE
61. ilding of tight construction air for combustion and ventilation must be obtained from outdoors When directly communication with the outdoors through vertical ducts two permanent openings located in the above manner shall be provided Each opening shall have a free area of not less than one square inch per 4000 Btuh of the total input of all appliances in the enclosure VENTING THE INSTRUCTIONS IN THIS SECTION ON VENTING MUST BE FOLLOWED TO AVOID CHOKED COMBUSTION OR RECIRCULATION OF FLUE GASES SUCH CONDITIONS CAUSE SOOTING OR RISKS OF FIRE AND ASPHYXIATION Heater must be protected from freezing downdrafts during shutdown periods The GPG 540A 650A and 750A water heater are classified as a category 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 classified as a category appliance positive vent pressure non condensing when installed with supplied sidewall vent kits or direct vent kit All regulations pertaining to the venting of these heaters must be followed The following vent installation instructions cover vertical horizontal and direct vent applications VERTICAL VENTING FOR GPG MODELS BAROMETRIC DRAFT CONTROL ASSEMBLY A double acting barometric draft control assembly is provided with any unit intended for chimney venting The purpose of this draft control is twofol
62. ime of installation and periodically thereafter to ensure a down draft condition does not exist DO NOT OBSTRUCT THE FLOW OF COMBUSTION AND VENTILATION AIR ADEQUATE AIR FOR COMBUSTION AND VENTILATION MUST BE PROVIDED FOR SAFE OPERATION EXTENDED NON USE PERIODS CATHODIC PROTECTION A CAUTION HYDROGEN GAS CAN BE PRODUCED IN AHOT WATER SYSTEM SERVED BY THIS HEATER THAT HAS NOT BEEN USED FOR A LONG PERIOD OF TIME GENERALLY TWO WEEKS OR MORE HYDROGEN GAS IS EXTREMELY FLAMMABLE To reduce the risk of injury under these conditions it is recommended that a hot water faucet be opened for several minutes before using any electrical appliance connected to the hot water system If hydrogen is present there will probably be an unusual sound such as air escaping through the pipe as the water begins to flow There should be not smoking or open flame near the faucet at the time it is open INSULATION BLANKETS A WARNING INSULATION BLANKET AVAILABLE TO THE GENERAL PUBLIC FOR EXTERNAL USE ON GAS WATER HEATERS ARE NOT APPROVED FOR USE ON YOUR STATE WATER HEATER THE PURPOSE OF AN INSULATION BLANKET IS TO REDUCE THE STANDBY HEAT LOSS ENCOUNTERED 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 CONJUNCTION WITH ASTATE WATER HEATER WILL ALSO VOID THESTATE W
63. in various ways Sensors mounted in the drain pan that trigger an alarm or turn off the incoming water to the water heater when leakage is detected Sensors mounted in the drain pan that turn off the water supply to the entire home when water is detected in the drain pan Water supply shut off devices that activate based on the water pressure differential between the cold water and hot water pipes connected to the water heater Devices that will turn off the gas supply to a gas water heater while at the same time shutting off its water supply 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 continuously and horizontally A 3 16 inch steel plate must cover the concrete blocks see Figure 2 NOTE If electrical conduits run under the floor of the proposed heater location insulate the floor as recommended above For appliances installation locations with elevations above 2000 feet 609 6 m refer to HIGH ALTITUDE INSTALLATIONS section a LA 8 52 12 MD XL 304 8 mm HEATER 3 16 STEEL E PLATE L3 L3 C3 C C3 CONCRETE BLOCK PROPER INSTALLATION ON COMBUSTIBLE FLOORIN
64. ipe In no case 45 elbow is equivalent to 5 feet 1 5 m of straight pipe In no case may the sum of the straight pipe lengths and the equivalent length of the elbows exceeds 80 feet 24 3 m Dimensions Supplied Inches mm Note the minimum vent diameter in Table 2 Refer to Table 3 for the correct vent terminal size for each heater The dimensions noted in Table 3 refer to Figure 5 TABLE mm Model Model C Dimensions GPV 540A VH 1 8 19 7 8 13 10 9 16 8 5 8 11 1 16 740A FIGURE 5 Use only the sidewall vent terminal supplied with the heater These terminals are specifically listed for use on these State heaters VENT TERMINAL LOCATIONS EXHAUST When considering location for sidewall vent terminals refer to the latest edition of the National Fuel Gas Code which recommends that vent terminals 1 Shall be located not less than 12 304 8 mm above grade 2 Shall be located not less than 7 feet 2 1 m above grade when adjacent to a public walkway 3 Shall terminate at least 3 feet 0 9 m above any forced air inlet within 10 feet 3 m 4 Shall terminate at least 4 feet 1 2 m below 4 feet 1 2 m horizontally from or 1 foot above any door window or gravity air inlet into any building 5 Shall not be closer than 3 feet 0 9 m from the inside corner of an L shaped structure 6 Shall be located above the snow line in geographical areas where snow accumulates VENT SYSTEM INSTALLATION
65. ir tn trito Lighting and Operating Label Sequence of Operation Water Temperature Control Adjustment Procedure Initial Start Up Adjustment Procedure for Fire Rate Low Nox and High Elevation Fine Tune nnne 24 26 GENERALINFORMATION sel Beta 27 Power Burner sed Thermostat i27 Highlimit mecca rere ee E errr cere 207 MAINTENANCE 27 Generale 2 4207 Maintenance Schedule 07 Electrical Servicing wel Flushing 27 Draining 28 Sediment Removal 28 lime Scale siete tei p eer COPI e Yeh 28 Relief Valve 28 29 Circulating PUND u lee 29 Low Emission Power Burner 2 29 Cleaning Flues 29 Barometric Draft Control 2 529 Vent Syster aiian ils 29 CHECKLIST AND SERVICE INFORMATION 29 30 TROUBLESHOOTING oi etae eb HR 30 32 R eplacerrient Parts 32 WARRANTY erlernen here 33 PARTS EIST ae teneis 34 39 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 amp 740A models are not available for use with Liquefied Petroleum or LP gas If
66. is operating The sounds are normal however the tank bottom should be cleaned Refer to MAINTENANCE for details 2 Some of the electrical components of the water heater make sounds which are normal e Contacts click or snap as the heater starts and stops Transformers often hum WATER LEAKAGE IS SUSPECTED 1 Check to see if the water heater drain valve is tightly closed Also check the cleanout opening for leakage 2 The apparent leakage may be condensation that forms on cool surfaces of the heater and piping 3 If the outlet of the relief valve is leaking it may represent Excessive water pressure Excessive water temperature Faulty relief valve Excessive water pressure is the most common cause of relief valve leakage It is often caused by a closed system If a check valve back flow preventer or pressure reducing valve is in 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 Installation of a second relief valve with lower setting than the primary relief valve An expansion tank of suitable size and pressure rating and provision to avoid water loggin
67. knob of gas control to the OFF position Refer to Step 5 of OPERATING INSTRUCTION above Replace thermostat control cover SEQUENCE OF OPERATION 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 prepurge cycle the pilot gas valve is energized At the same time the electronic spark generator in the module produces a high voltage spark pulse output The voltage generates a spark at the ignitor that lights the pilot If the pilot does not light or flame signal is less than 1 micro A within 15 seconds system locks out and must be reset by turning burner switch OFF for a minimum of 1 minute During system lockout blower still runs When the pilot flame is established flame is sensed by flame rod the main gas valve is energized Main gas flows to main burner where it s ignited by the pilot flame Now heater is in Heating Mode During the Heating Mode If gas line pressure drops below the setting point the flame module is de energized gas valves closed blower still runs If gas line pressure drops below the setting point then gas line pressure increases to above the setpoint heater starts again from purging cycle If gas line pressure fluctuates around t
68. l void the warranty If you have not already done so contact your local State Sales Representative or Authorized GPG GPV Start Up Agent and set up a date for the start up service The time to ask any questions you may have about your unit is when the State Authorized GPG GPV Start Up Agent is there Please do not hesitate to ask the agent any questions which you may have regarding the units start up operation or maintenance A CAUTION BEFORE PROCEEDING WITH THE OPERATION OF THE UNIT MAKE SURE HEATER AND SYSTEM ARE FILLED WITH WATER AND ALL AIR IS EXPELLED FROM HEATER AND 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 19 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 and piping to be filled 4 Close the hot water faucet as water starts to flow 5 The heater is ready to be operated PURGING Gas line purging is required with new piping or systems in which air has entered A CAUTION PURGING SHOULD BE PERFORMED BY PERSONS EXPERIENCED IN THIS TYPE GAS SERVICE TO AVOID RISK OR FIRE OR EXPLOSION PURGE DISCHARGE MUST NOT ENTER CONFINED AREA OR SPACES WHERE IGNITION CAN OCCUR THE AREA MUST BE WELL VENTILATED AND ALL
69. ments One sensor is located near the top of the tank and the other is near the center The thermostat is set in the lowest position before the heater leaves the factory dial is adjustable and may be set for 120 49 C to 180 F 82 C water temperature but 120 F 49 C is the recommended starting point It is suggested the dial be placed on the lowest setting which produces an acceptable hot water supply This will always give the most energy efficient operation The temperature control has a 4F fixed differential ADJUSTMENT PROCEDURE Initial Start Up A minimum dynamic gas supply pressure of 8 w c for natural gas is required before making any adjustment to the gas control pressure regulator Attempts to adjust the regulator during periods of low gas supply pressure could result in overfiring of the heater when the gas supply pressure returns to normal 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 gas manifold pressure see Table 10 using a manometer connected to the manifold pressure tap on the Robertshaw gas control valve see Figure 10 Important Note Use gas manifold pressure as initial setup only The final air and gas
70. metric draft control see VENTING 3 If the burner operation is still noisy then remove the burner examine the burner diffuser blast tube tip anti flashback corrugated tube center mixing refer to the burner manual for details GAS FAILS TO SHUT OFF Check for defective gas valve or thermostat incorrect replace If operation is REPLACEMENT PARTS Replacement parts may be ordered through State dealers unauthorized servicers or distributors Refer to the Yellow Pages for where to call or contact the State Water Heaters 500 Lindahl Parkway Ashland City TN 37015 1 800 821 2017 or visit our website at www statewaterheaters com When ordering parts be sure to state the quantity part number and description of the items including the complete model and serial number as it appears on the product Refer to the parts list for more information Model GPG GPV Limited Warranty State Industries Inc the warrantor extends the following LIMITED WARRANTY to the owner of this water heater 1 THE TANK 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 THREE years after installation the warrantor will supply a complete new State water heater of equivalent size and current model Some government agencies are requiring energy efficient standards for water heaters In the event regulations prohibit sale of a
71. model of equivalent size and construction State will provide a model which complies with the regulations of your area in which case the consumer will be charged the difference in price between the like replacement and the energy efficient model required The warranty on the replacement water heater will be limited to the unexpired term of the original warranty ALL OTHER PARTS If within ONE year after initial installation of this water heater any part or portion shall prove upon examination by the warrantor to be defective in material or workmanship the warrantor will repair or replace such part or portion at its option CONDITIONS AND EXCEPTIONS This warranty shall supply only when the water heater is installed in accordance with local plumbing and building codes ordinances and regulations the printed instructions provided with it and good industry practices In addition a temperature and pressure relief valve certified by A G A and approved by the American Society of Mechanical Engineers must have been installed a This warranty shall apply only when the heater is used 1 used at temperatures not exceeding the maximum calibrated setting of its thermostat 2 used at water pressure not exceeding the working pressure shown on the heater 3 filled with potable water free to circulate at all times and with the tank free of damaging water sediment or scale deposits 4 used in a non corrosive and non contaminated atmosphere 5
72. n the damper center bolt Adjustment for Low NOx Emission Application The water heater is preset at factory for Low Nox emission combustion Due to the installation variations fine tune adjustments may be required To lower NOx emission level corrected at 3 O or lower is required by SCAQMD air damper setting may need to be slightly increased To increase air damper setting loosen the center nut of the inlet air damper rotate the damper clockwise slightly then tighten the center nut After re set the air damper cycle heater ON OFF and check fire rate and flue gas CO O reading Adjustment for High Elevation Application Installation above 2000 feet sea level require new air damper settings All the final settings should be based on flue gas CO O reading see Table 10 To increase air damper setting loosen the center bolt of the inlet air damper rotate the damper clockwise slightly then tighten the center bolt After re setting the air damper cycle heater ON OFF and check fire rate and flue gas COO reading A WARNING UNDER NO CIRCUMSTANCES SHOULD THE INPUT RATE EXCEED THE INPUT RATE SHOWN IN THE HEATER RATING PLATE OVERFIRING COULD RESULT IN DAMAGE OR SOOTING OF THE HEATER SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF TURN OFF THE MANUAL GAS CONTROL VALVE TO THE APPLIANCE AIR SWITCH a Se BURNER ON OFF SWITCH FLAME CONTROL MODULE Pas ge GAS PRESSURE SWITCH
73. ntrol clockwise to OFF position Figure A Waitfive 5 minutes to clear out any gas If you then smell gas Turn top knob of gas control counterclockwise to ON Figure B STOP Follow B in the safety information above on this label If you don t smell gas go to next step 8 9 Turn on all electric power to the appliance Set thermostat to desired setting Turn switch to ON position Heater will automatically begin operation Blower motor will run approximately 40 seconds then pilot gas valve will open Upon confirming the pilot flame the main gas valve will open and the heater will operate in heating mode Reference Sequence of Operation section of manual for details Heater is equipped with an ignition module which locks out after one 1 unsuccessful ignition attempt Blower motor will continue to run If lockout occurs turn burner switch to OFF position for at least one minute then turn the switch backto ON Heater will automatically begin operation Replace thermostat control cover Ifthe appliance will not operate follow the instructions TO TURN OFF GAS APPLIANCE and call your service technician or gas supplier TO TURN OFF GAS TO APPLIANCE Remove thermostat control cover Set thermostat to lowest setting Turn burner switch to OFF 22 4 Turn off all electric power to the appliance if service is to be performed Turn top
74. o smell next to the floor because some gas is heavier than air and will settle on the floor WHATTO DO IF YOU SMELL GAS Donottry to light any appliance Donottouch any electric 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 FIGURE A OFF POSITION e Ifyou cannot reach your gas supplier call the fire department C Use only your hand to push in or turn the gas control knob Never use tools If the knob will not push in or turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water Do not operate appliance unless unit is filled with water and inlet lines are fully open FIGURE B ON POSITION OPERATING INSTRUCTIONS Remove appliance thermostat cover Rotate thermostat dial counterclockwise to lowest setting r STOP Read the safety information above on this label Turn off all electric power to the appliance This appliance is equipped an ignition device which automatically lights the burner Do NOT try to light the burner by hand Refer to diagrams above Turn top knob of gas co
75. on premix power burner and must be started adjusted by a State Authorized GPG GPV Start Up Agent HIGH LIMIT SWITCH E C O The dual bulb controller also contains the high limit energy cutoff sensor The high limit switch interrupts main burner gas flow should the water temperature reach 205 F 96 C In the event of high limit switch operation the appliance cannot be restarted unless the water temperature is reduced by 20 F 11 C approx and the high limit reset button on front of limit control is depressed see Figure 1 THERMOSTAT TEMPERATURE DIAL HIGH LIMIT MANUAL RESET BUTTON FIGURE 1 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 setting The water temperature would continue to rise until high limit switch operation An improper thermostat setting for a short repetitive usage pattern may lead to a stacking effect This causes a temperature gradient increasing from the bottom to the top of the tank It is possible that the water at the high limit switch sensor could reach its maximum temperature before the water temperature at the thermostat reaches the dial setting causing the high limit switch to activate
76. r damper outside of its adjustment range of the rated fire rate unless authorized by a State Service Center Important Note Final gas and air settings should be based on flue gas CO or O reading see Table 10 Increase burner manifold pressure will increase fire rate and flue gas CO reading Increase air damper setting will decrease fire rate and decrease flue gas CO reading Adjustable air damper is preset for the rated fire rate prior to delivery should not be re adjusted unless 24 its 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 c 2 kPa or higher when the heater is running Remove the pressure regulator cover screw Figure 10 and adjust the pressure by tuning the adjustment screw w a small screwdriver clockwise to increase gas pressure into the burner and fire rate Counterclockwise to decrease gas pressure and input rate Clock gas meter repeat above Step b to achieve the specific input rate Measure flue gas O and or CO see Table 10 for acceptable range If the O or CO reading is within the acceptable range then proceed to Step f If the O or CO reading is out of range adjust air damper is required Repeat Steps b c d if air damper is adjusted Cycle heater ON OFF Replace the gas regulator cover pressure tap and tighte
77. r testing procedures f pilot flame is confirmed visually through the burner peek hole and the flame signal is zero the thermal cutoff safety Switch mounted nearby the flame rod inside the burner mixing chamber may be broken or check for loose wire connections or low gas switch mounted inside control panel may be broken If the thermal cutoff switch or low gas switch is broken by checking the switch continuity the switches must be replaced before the heater can operate again If it s confirmed that the thermal cutoff switch is damaged open call the State Technical Center to analyze the root cause too lean combustion and proper gas air ratio adjustment Flashback will cause the thermal cutoff switch broken open Ifthe flame signal is not zero but below 1p4A relocate flame rod or replace flame rod will be required Refer to burner manual for detailed procedure of replacing flame rod MOTOR RUNS CONTINUOUSLY BURNER LIGHTS ON MOMENTARILY THEN LOCKS OUT OR EXCESSIVE ON OFF CYCLE 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 the valve check loose wire connection 3 Check for gas supply line pressure The gas line pressure before
78. rected In some cases a special vent cap may be required A WARNING Failure to correct back drafts may cause air contamination and unsafe conditions Do not connect the heater to a common vent or chimney with solid fuel burning equipment This practice is prohibited by many local building codes as is the practice of venting gas fired equipment to the ductwork of ventilation systems Connectors shall not be connected to a chimney vent or venting system served by a power exhauster unless the connection is made on the negative pressure side of the exhauster Do not connect any heater vented by natural draft to any vent serving mechanical draft equipment operating under positive vent pressure such as category Ill or category IV appliances HORIZONTAL SIDE WALL VENTING FOR GPV MODELS An exhaust vent hood vent hood and a flue reducer are supplied with any unit intended for through the wall horizontal venting These parts must be installed without alteration The vent hood adapter is designed for use with Selkirk Metalbestos Model PS or Model G venting see Figure 7 on page 10 Refer to Table 2 for limitations of venting system design for horizontal venting TABLE 2 po P GPV 540A 740A Flue Reducer 9 x 8 228 6 x 203 2 Maximum Number 90 4 Maximum Total Vent System 15 Length Equiv Feet Meters When calculating the equivalent length of a venting system each 90 elbow is equivalent to 10 feet 3 m of straight p
79. rwarding the new heater or replacement part from the nearest distributor and returning the claimed defective heater or part to such distributor C All cost necessary or incidental for material and or permits required for installation of the replaced heater or part LIMITATIONS ON IMPLIED WARRANTIES Implied warranties including the warranty of merchantability imposed on the sale of this heater under state law are limited to one 1 year duration for the heater or any of its parts Some states do not allow limitation on how long an implied warranty lasts so the above limitation may not apply to you CLAIM PROCEDURE Any claim under the warranty should be initiated with the dealer who sold the heater or with any other dealer handling the warrantor s products If this is not practicable the owner should contact State Water Heaters 500 Lindahl Parkway Ashland City TN 37015 Telephone 1 800 323 2636 a The warrantor will only honor replacement with identical or similar water heater or parts thereof which are manufactured or distributed by the warrantor b Dealer replacements are made subject to in warranty validation by warrantor DISCLAIMERS NO OTHER EXPRESS WARRANTY HAS BEEN OR WILL BE MADE IN BEHALF OF THE WARRANTOR WITH RESPECT TO THE MERCHANTABILITY OF THE HEATER OR THE INSTALLATION OPERATION REPAIR OR REPLACEMENT OF THE HEATER THE WARRANTOR SHALL NOT BE RESPONSIBLE FOR WATER DAMAGE LOSS OF USE OF THE UNIT INCONVENIENCE
80. see Figure 7 Attach Selkirk Metalbestos model PS or model G venting to the seal ring following the venting manufacturer s instructions For total safety it is recommended that only venting listed for use with category III appliances positive vent pressure non condensing should be used between the heater and the vent hood even through national or local codes may allow the use of type B or single wall vent 5 Install the remaining vent sections back to the heater following the venting manufacturer s instructions on assembling and sealing joints Follow good venting practice regarding properly supporting vent system and keeping the number of offsets to a minimum See Table 2 for the maximum allowable number of elbows in venting system 6 Install the flue reducer included with the exhaust hood between the vent system and the heater 7 Seal all vent connections and venting with sealants supplied by vent pipe manufacturer or with a high temperature silicone sealant suitable for continuous temperatures of 500 F 260 C Acceptable sealant include Dow Corning 736 or equivalent INTAKE VENT HOOD MUST NEVER BE MOUNTED VENT HOOD MUST BE MOUNTED 1 30 m MINIMUM ABOVE 30 m MIN EXHAUST VENT HOOD DOORS AND WINDOWS lt EXHAUST INTAKE VENT HOODS 1 20 m MIN MUST BE MOUNTED 3 9144 m MIN FROM EXHAUST HOODS VENT iE INTAKE VENT HOOD 3 9144 m MIN 4 1 2 m VENT HOOD MUST
81. sight port on the burner mounting plate Burner flame should be kept blue At least annually contact a qualified service agency for burner cleaning and other routine maintenance For burner related Maintenance Schedule Troubleshooting Flame Rod Ignitor Thermal Cut Off Switch Replacement Procedures use burner Operation amp Maintenance Manual provided with this heater CLEANING FLUES The following describes how to gain access to the tank flues for cleaning if necessary 1 Turn off the heater electrical disconnect switch 2 Remove the vent connector from on top of the heater 3 Remove the jacket top from the heater by taking out the screws and lifting it off Remove the insulation from the top of the heater Remove the inner cover by taking out the pipe collar around the water inlet and outlet nipple The flue baffles may now be removed by lifting out Using a wire brush a nylon brush must not be used remove soot from flue passages in heater tank A CAUTION While cleaning tank flue passages care must be taken that brush does not come in contact with neither the combustion chamber lining nor the baffle or funnel 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 MODEL
82. the valve should be maintained at minimum 8 w c when main flame is ON If the gas line pressure drops below 8 w c 2 kPa the service regulator pressure setting must be increased to keep 8 w c 2 kPa minimum gas pressure After adjusting the gas regulator setting turn off the heater make sure the gas line pressure does not exceed 14 w c 3 5 kPa if it does exceed 14 w c 3 5 kPa static pressure the gas supply line size must be increased accordingly to avoid gas line pressure exceeding 14 w c 3 5 kPa 4 Check the gas valve manifold pressure refer to Table 10 see ADJUSTMENT PROCEDURE to adjust the manifold pressure 5 Check for defective gas valve for failing to open or shut off 6 Verify that the air supply is adequate The air inlet screen or blower wheel may be restricted 7 Check the installation for proper ventilation see AIR REQUIREMENTS 8 Verify the air switch setting is not too high 9 Check the venting system for the correct sizing excessive or insufficient draft and proper operation of the barometric draft control see VENTING NOISY BURNER OPERATION 1 Check for flue gas excess O or CO reading refer to Table 10 If combustion is too lean flue gas O reads more than 7 5 the combustion flame front may not be stable which will cause noisy operation See ADJUSTMENT 2 Check the venting system for the correct sizing excess or insufficient draft and proper operation of the baro
83. tion for at least one minute to reset the heater e Check for 24V between PV terminal and MV PV terminal after 45 seconds prepurge cycle this 24V may only last 15 seconds starting after 45S prepurge If there s no 24V at the PV terminal ever and there s 24V at 24V terminal the Honeywell flame control module needs to be replaced f 24V is detected for a period of 15 seconds check for the changes of gas supply line pressure when the pilot gas valve is energized If no visible pressure change during the pilot ignition period check for loose connection of the pilot valve or a defective pilot gas valve Adjust the pilot gas regulator setting during the pilot ignition period 15 seconds Do not set too much or too little pilot gas This adjustment should only be performed during the 15 seconds ignition period A clockwise or counter clockwise 0 5 to 1 turn should be able to correct the problem Refer to burner manual for detailed pilot gas setting procedure If still no pilot flame inside the burner check for the spark ignitor wiring ignitor tip location and visually check the spark burner pilot assembly needs to be taken out for the visual check Refer to the burner manual for detailed spark ignition troubleshooting procedures 6 Pilot flame established but not detected by the flame control module Use Micro Amp meter to measure flame signal during the pilot ignition period Refer to burner manual fo

State Industries GPG-650A Water Heater User Manual

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