State Water Heaters GPG 81-140 Instruction Manual Download Page 50 | Manualshive

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50

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.

prior to start up

important

Factory Start-up is required for activating warranty and assuring maximum

operating performance. Contact your local sales representatives or

Authorized Start-up Agent to arrange a Free Certified Start-up.

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Summary of Contents for GPG 81-140

Page 1: ...nergy efficient water heater We appreciate your confidence in our products WARNING If the information in these instructions is not followed exactly a fire or explosion may result causing property damage personal injury or death Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any applia...

Page 2: ...grams 35 49 MANIFOLD KITS 50 replacement parts list 51 52 Notes 53 54 Warranty 55 Table Of Contents Safe Installation Use and Service 3 Approvals 3 General Safety Information 4 5 Precautions 5 Grounding Instructions 5 Hydrogen Gas Flammable 5 Introduction 6 Abbreviations Used 6 Qualifications 6 Start Up Requirements 6 Preparing for the Installation 6 Features And Components 7 High Limit Switch 7 E...

Page 3: ...other reproductive harm and requires businesses to warn of potential exposure to such substances WARNING This product contains a chemical known to the State of California to cause cancer birth defects or other reproductive harm This appliance can cause low level exposure to some of the substances listed in the Act DANGER WARNING CAUTION CAUTION DANGER indicates an imminently hazardous situation wh...

Page 4: ...tion Contact a qualified installer or service agency for installation and service Excessive gas pressure to gas valve can cause serious injury or death Do not use water heater with any gas other than the gas shown on the rating label Turn off power to the water heater before performing any service Electrical Shock Hazard Label all wires prior to disconnecting when performing service Wiring errors ...

Page 5: ...ater 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 no smoking or open flame near the faucet at the time it is open General Safety Information Verify the power to the water heater is turned off before performing any service procedures Read and understand this instruction manual and the safety m...

Page 6: ...ct is limited and could be void in the event the unit is not installed per the instructions in this manual and or not started up by an authorized factory trained service start up provider Preparing For The Installation 1 Read the General Safety section page 4 5 of this manual first and then the entire manual carefully If you don t follow the safety rules the water heater will not operate properly ...

Page 7: ...e water heater IGNITION MODULE FIGURE 2 BAROMETRIC DRAFT CONTROL The heater is equipped with a double acting barometric draft control This control assembly is factory adjusted to automatically regulate the chimney draft imposed on the unit BAROMETRIC DRAFT CONTROL FIGURE 3 COMBUSTION CHAMBER OBSERVATION PORT The combustion chamber observation access panel is located above and to the left of the bu...

Page 8: ...P WT LBS IN OUT ASME STD GPG 81 140 74 3 4 65 26 3 4 6 21 3 8 27 3 4 38 85 1 4 1 2 658 556 1 1 2 1 1 2 GPG 81 199 74 3 4 65 26 3 4 6 21 3 8 27 3 4 38 85 1 4 1 2 635 545 1 1 2 1 1 2 GPG 81 270 74 3 4 65 26 3 4 8 21 3 8 27 3 4 38 85 1 4 3 4 632 547 1 1 2 1 1 2 GPG 81 370 74 3 4 65 26 3 4 8 21 3 8 27 3 4 38 85 1 4 3 4 731 634 1 1 2 1 1 2 ...

Page 9: ...9 256 5 Models with letter A following the model number have the optional ASME tank construction The GPG 81 370 is available in natural gas only TABLE 3 GAS AND ELECTRICAL CHARACTERISTICS Model Type of Gas Gas Supply Pressure Gas Manifold Pressure Volts Hz Amperes Minimum Maximum All Models Natural 4 5 W C 1 12 kPa 14 W C 3 48 kPa 3 5 W C 0 87 kPa 120 60 5 All Models Propane 4 5 W C 1 12 kPa 14 W ...

Page 10: ...24 cm 24 60 96 cm locating the water heater Property Damage Hazard All water heaters eventually leak Do not install without adequate drainage CAUTION When installing the heater consideration must be given to proper location Location selected should be as close to the stack or chimney as practicable with adequate air supply and as centralized with the piping system as possible Fire or Explosion Haz...

Page 11: ...tions exist water softening or the threshold type of water treatment is recommended This will protect the dishwashers coffee urns water heaters water piping and other equipment See the Maintenance Section in this manual for sediment and lime scale removal procedures Circulation pumps A circulating pump is used when a system requires a circulating loop or there is a storage tank used in conjunction...

Page 12: ...eet 1219m you subtract 4 once for each thousand feet x 04 4 input reduction x 78 000 original rating from the original rating Therefore to calculate the input rating at 4 000 feet 1219m 4 x 04 x 78 000 12 480 Btuh 3 7 Kwh 78 000 22 9 Kwh 12 480 3 7 Kwh 65 520 Btuh 19 2 Kwh At 6000 feet 1829m the correct input rating should be 59 280 Btuh 17 4 Kwh CIRCULATING PUMP WIRING DIAGRAM STORAGE TANK OR BUI...

Page 13: ...g at maximum rate dynamic pressure The gas supply pressure must be stable within 1 5 W C from static to dynamic pressure to provide good performance Pressure drops that exceed 1 5 W C may cause rough starting noisy combustion or nuisance outages Increases or spikes in static pressure during off cycles may cause failure to ignite or in severe cases damage to appliance gas valves If your low pressur...

Page 14: ...the Water Piping Diagrams beginning on page 35 Temperature pressure relief valve Explosion Hazard Temperature Pressure Relief Valve must comply with ANSI Z21 22 CSA 4 4 and ASME code Properly sized temperature pressure relief valve must be installed in opening provided Can result in overheating and excessive tank pressure Can cause serious injury or death This water heater is provided with a prope...

Page 15: ... Pressure Relief Valve call the toll free number listed on the back cover of this manual for technical assistance Contaminated Air Breathing Hazard Carbon Monoxide Gas Install water heater in accordance with the Instruction Manual and NFPA 54 or CAN CSA B149 1 To avoid injury combustion and ventilation air must be taken from outdoors Do not place chemical vapor emitting products near water heater ...

Page 16: ...ce A Confined Space is one whose volume is less than 50 cubic feet per 1 000 Btu hr 4 8 cubic meters per kW of the total input rating of all appliances installed in the space Openings must be installed to provide fresh air for combustion ventilation and dilution in confined spaces The required size for the openings is dependent on the method used to provide fresh air to the confined space and the ...

Page 17: ...inches 300 mm of the top of the enclosure shall be provided See Figure 12 The water heater shall have clearances of at least 1 inch 25 mm from the sides and back and 6 inches l50 mm from the front of the water heater The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces that freely communicate with the outdoors...

Page 18: ...he aggregate input rating of all appliances installed in the enclosure Each opening shall not be less than 100 square inches 645 cm2 Outdoor Air Through Two Vertical Ducts The illustrations shown in this section of the manual are a reference for the openings that provide fresh air into confined spaces only Do not refer to these illustrations for the purpose of vent installation See Venting Install...

Page 19: ... on the water heater each remote storage tank that may be installed and piped to a water heating appliance must also have its own properly sized rated and approved Temperature Pressure Relief Valve installed Call the toll free technical support phone number listed on the back cover of this manual for further assistance in sizing a T P valve for remote storage tanks T P Valve Discharge Pipe Explosi...

Page 20: ... recommended that the discharge pipe be terminated at an adequate drain inside the building Shall not have any valve or other obstruction between the relief valve and the drain Installation Diagrams Top Inlet Outlet Usage Use of the top inlet water connection requires an inlet dip tube refer to Figure 17 The tube is supplied in the heater Follow caution labels if applying heat to this fitting Do n...

Page 21: ...ing jurisdiction AN ELECTRICAL GROUND IS REQUIRED TO REDUCE RISK OF ELECTRICAL SHOCK OR POSSIBLE ELECTROCUTION If any of the original wire as supplied with the water heater must be replaced use only type 105 C thermoplastic or equivalent 2500 C type F must be used for the flame sensor and igniter leads The controls of this water heater are polarity sensitive Be certain to properly wire the hot and...

Page 22: ...s in 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 is clean on the inside To trap any dirt or foreign material in the gas supply line a sediment trap must be incorporated in the piping see Figure 20 The sediment trap must be rea...

Page 23: ... escape 3 Fully open the cold water inlet valve allowing the piping and water heater to fill with water 4 Close hot water faucet opened in Step 2 as water starts to flow Read SEQUENCE OF OPERATION section of this manual prior to lighting and operating this water heater With above conditions satisfied start the unit in accordance with the instructions on the operating label attached to the heater F...

Page 24: ...ET IF NO SPARK S89 LOCKS OUT AND SHUTS DOWN SYSTEM MUST BE RESET IF FLAME SIMULATION CONDITION IS PRESENT SYSTEM WILL NOT START POWER INTERUPTION SYSTEM SHUTS OFF RESTARTS WHEN POWER IS RESTORED SAFE START CHECK VALVE ON DELAY 30S PREPURGE COMBUSTION AIR BLOWER STARTS SPARK GENERATOR POWERED IGNITION BEGINS AND GAS CONTROL OPENS BURNER LIGHTS IGNITION STOPS AND FLAME CURRENT IS SENSED BURNER RUNS ...

Page 25: ...25 LIGHTING OPERATION LABEL Figure 21 Label for Natural AND LP Gas Models ...

Page 26: ...to assure proper venting and correct combustion CHECKING THE INPUT For installation locations with elevations above 2000 feet refer to HIGH ALTITUDE INSTALLATIONS section of this manual for input reduction procedure The input rate can be estimated by timing the meter if no other appliances are operating With a stopwatch or a wristwatch which can display the time in seconds read the gas meter and m...

Page 27: ...est of the flue gases with an Orsat or other similar combustion test equipment If the CO2 content is within range see Table 9 no adjustment of the air shutter is required Flue gas temperature and CO2 measurements should be repeated 3 times to ensure accurate readings Check the flue gas temperature ahead of the barometric damper See Table 9 net temp gross temp ambient temp Check breeching pressure ...

Page 28: ... the limited warranty Thermal expansion tanks must be installed on all closed water systems DO NOT PLUG THE TEMPERATURE PRESSURE RELIEF VALVE OPENING THIS CAN CAUSE PROPERTY DAMAGE SERIOUS INJURY OR DEATH venting system and BAROMETRIC DRAFT CONTROL The heater is equipped with a double acting barometric draft control This control assembly is factory adjusted to automatically regulate the chimney dr...

Page 29: ...o reduces efficiency of the heater and increases fuel consumption The usage of water softening equipment greatly reduces the hardness of the water However this equipment does not always removeallofthehardness lime Forthisreasonitisrecommended that a regular schedule for deliming be maintained The time between cleaning will vary from weeks to months depending upon water conditions and usage The dep...

Page 30: ... the tank due to a by pass problem or defective cold water inlet valve Also check for clogged drain valve opening Heater must be completely drained before introducing UN LIME 8 Remove the cleanout cover and place a clean plastic bucket next to the cleanout opening Partially open the cold water inlet valve to allow time to accomplish the following and then close the valve Figure 25 deliming solvent...

Page 31: ...er gasket part number 9004099215 Remove the drain valve 9 Install the long plastic male adapter insert fitting into the drain valve opening of heater after applying Teflon tape or paste to threads Tighten firmly by hand and use wrench or adjustable pliers to check for secure connection Do not over tighten to avoid damage to threads and fittings Prepare the Up N Down Transfer Kit The next step is t...

Page 32: ...ng against diagram check for grounded broken or loose wires Check all wire ends to be sure that they are making good contact ELECTRICAL SERVICING LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION VERIFY PROPER OPERATION AFTER SERVICING Gas Control Valve Figure 30 shows the combination gas control valves used on these heaters If ...

Page 33: ...e If rumbling persists call a qualified service agency Delime heater Ticking or metallic sounds Expansion and contraction normal Pounding water hammer Air chambers in piping have become waterlogged Thermal expansion tank damaged improperly charged or improperly sized Drain piping system and refill Heater must be off while this is being done Check thermal expansion tank charge pressure when the wat...

Page 34: ...imit switch operation the water heater cannot be restarted unless the water temperature is reduced to approximately 120F 49C The high limit reset button on the front of the thermostat then needs to be depressed See Figure 2 for the location of the reset button start up conditions SMOKE ODOR It is not uncommon to experience a small amount of smoke and odor during the initial start up This is due to...

Page 35: ... s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control MULTI FLUE 1 UNIT WITH VERTICAL STORAGE TANK LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WIT...

Page 36: ...mostat should be set 5 degrees F higher than the Tank Temperature Control MULTI FLUE 1 UNIT WITH HORIZONTAL STORAGE TANK LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES A...

Page 37: ...s and the storage tank s MULTI FLUE 1 UNIT WITH MIXING VALVE TWO TEMPERATURE LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL REQUIREMENTS TE...

Page 38: ...ump between the water heater s and the storage tank s MULTI FLUE 2 UNITS LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL REQUIREMENTS HOT WA...

Page 39: ...stat should be set 5 degrees F higher than the Tank Temperature Control MULTI FLUE 2 UNITS WITH VERTICAL STORAGE TANK LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ...

Page 40: ...stat should be set 5 degrees F higher than the Tank Temperature Control MULTI FLUE 2 UNITS WITH VERTICAL STORAGE TANK LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ...

Page 41: ...at should be set 5 degrees F higher than the Tank Temperature Control MULTI FLUE 2 UNITS WITH HORIZONTAL STORAGE TANK LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ...

Page 42: ...TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL REQUIREMENTS BOOSTER WATER RETURN PRE HEATED WATER TO BOOSTER BOOSTER WATER TO FIXTURES HOT WATER T...

Page 43: ...F VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL REQUIREMENTS EXPANSION TANK BOOSTED WATER OUTLET TYPICAL BOOSTER HEATER PRE HEATER PRE HEATER MUST BE IDENTICAL HEATERS FINISHED FLOOR COLD WATER S...

Page 44: ... LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL REQUIREMENTS HOT WATER TO FIXTURES HOT WATER RETURN COLD WATER SUPPLY EXPANSION TANK PIPE T...

Page 45: ... than the Tank Temperature Control MULTI FLUE 3 UNITS WITH VERTICAL STORAGE TANK LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL REQUIREMENT...

Page 46: ...er than the Tank Temperature Control MULTI FLUE 3 UNITS WITH HORIZONTAL STORAGE TANK LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL REQUIRE...

Page 47: ...URE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL REQUIREMENTS EXPANSION TANK COLD WATER SUPPLY HOT WATER TO FIXTURES FINISHED FLOOR HOT WATER RETURN PIPE T ...

Page 48: ...Temperature Control MULTI FLUE 4 UNITS WITH VERTICAL STORAGE TANK LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL REQUIREMENTS HOT WATER TO ...

Page 49: ...k Temperature Control MULTI FLUE 4 UNITS WITH HORIZONTAL STORAGE TANK LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL REQUIREMENTS HOT WATER...

Page 50: ...rometric draft control assemblies combustion clearances and servicing must be added PRIOR TO START UP IMPORTANT Factory Start Up is required for activating warranty and assuring maximum operating performance Contact your local sales representatives or Authorized Start Up Agent to arrange a FREE Certified Start Up ...

Page 51: ...G 81 140 HSG 200 62459 001 0 24 62459 001 0 209 GPG 81 199 HSG 200 62459 001 0 38 62459 001 0 257 GPG 81 270 HSG 400 62459 002 0 368 62459 002 0 302 GPG 81 370 HSG 400 62459 002 0 532 62459 002 0 386 MAIN BURNER ORIFICE CHART COMMERCIAL GAS Glass Lined Tank Type Water Heater REPLACEMENT PARTS LIST 51 ...

Page 52: ...tric Draft Control w Tee Assy 9500007199 9500007199 9500007200 9500007200 Cleanout Assembly 4 Gasket 9004099215 9004099215 9004099215 9004099215 5 Pressure Plate 9005797205 9005797205 9005797205 9005797205 6 Screw Self Tapping Req d 9004100215 9004100215 9004100215 9004100215 7 Cover Cleanout Opening 181260 181260 181260 181260 8 Thermostat with ECO 9004529005 9004529005 9004529005 9004529005 9 Va...

Page 53: ...notes 53 ...

Page 54: ...notes 54 ...

Page 55: ... acceptable method 4 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 but are not limited to a Labor charges for service removal repair or reinstallation of the water heater or any component part b Shipping delivery handling and administrative charges...

Page 56: ...Copyright 2013 State Industries Inc All rights reserved 500 Tennessee Waltz Parkway Ashland City TN 37015 Technical Support 800 365 8170 Parts 800 821 2017 www statewaterheaters com ...

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