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State Industries GPV-540A - page 1
1 MODELS GPG/GPV-540A, 650A AND 740A COMMERCIAL GAS, GLASS-LINED, TANK-TYPE LOW NOx WA TER HEA TER P ART NO. 195047-000 CAUTION TEXT IN BLACK BOLD TYPE OR UNDERLINED CONT AINS INFORMA TION RELA TIVE TO YOUR SAFETY . PLEASE READ THOROUGHL Y BEFORE INST ALLING AND USING THIS APPLIANCE . ASHLAND CITY , T N www.statewaterheaters.com PLACE THESE INSTRUC ...
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State Industries GPV-540A - page 2
2 FOREWORD The design of the GPG 540A through 740A models complies with ANSI Z21.10.3/CSA 4.3 as an automatic circulating tank and an automatic instantaneous type heater . The GPV 540A through 740A models are designed for sidewall venting and direct venting applications and are certified under UL 795. Detailed installation diagrams are found in thi ...
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State Industries GPV-540A - page 3
3 are different from natural gas models. A natural gas heater will not function safely on LP gas and no attempt should be made to convert a heater from natural gas to LP gas. GPG/GPV-540A, 650A & 740A models are not available for use with Liquefied Petroleum or LP gas. If you have obtained a GPG/GPV-540A, 650A or 740A model with the intent to u ...
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State Industries GPV-540A - page 4
4 and sodium chloride (water softener salt), waxes, and process chemicals are typical compounds which are potentially corrosive. Do not store products of this sort near the heater . Also, air which is brought in contact with the heater should no contain any of these chemicals. If necessary , uncont aminated air should be obtained from remote or out ...
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State Industries GPV-540A - page 5
5 Continued manual resetting of high limit control, preceded by higher than usual water temperature is evidence of high limit switch operation. The following are possible reasons for high limit switch operation. • A malfunction in the thermostatic controls would allow the gas valve to remain open causing water temperature to exceed the thermostat ...
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State Industries GPV-540A - page 6
6 Units, which are to be installed on combustible flooring, must be supported by a full layer of hollow concrete blocks, from 8” (203.2 mm) to 12” (304.8 mm) thick and extending 12” (304.8 mm) minimum beyond the heater in all directions. The concrete blocks must provide an unbroken concrete surface under the heater with the hollows running co ...
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State Industries GPV-540A - page 7
7 Heater must be protected from freezing downdrafts during shutdown periods. The GPG 540A, 650A and 750A water heater are classified as a category I appliance (non-positive vent pressure, non- condensing) when installed with the supplied barometric draft control assembly in a vertical vent installation. The GPV 540A through 740A heater is classifie ...
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State Industries GPV-540A - page 8
8 Refer to T able 2 for limitations of venting system design for horizontal venting. T ABLE 2 GPV-540A-740A Flue Outlet Dia. (Inches/mm) 9” (228.6) Flue Reducer 9” x 8” Dimensions -Supplied (Inches/mm) 228.6 x 203.2 Minimum Outlet V ent Dia. (Inches/mm) 8” (203.2) Maximum Number 90° 4 Of Elbows 45° 8 Maximum T otal V ent System 75 Length, ...
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State Industries GPV-540A - page 9
9 DIRECT VENTING - FOR GPV MODELS All exhaust vent terminal, flue reducer , and intake vent terminal are supplied with any unit intended for direct venting. These parts must be installed without alteration. This heater is category III appliance when used in a direct vent application. All national and local codes pertaining to the installation of su ...
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State Industries GPV-540A - page 10
10 1. Shall be located not less than 12” (304.8 mm) above grade. 2. Shall be located not less than 3 (.9144 m) feet horizontally from and not less than 3 feet (.9144 m) below an exhaust vent terminal. 3. Shall not be located directly above an exhaust terminal. 4 . Shall be located 12” (304.8 mm) above the snow line in geographical areas where s ...
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State Industries GPV-540A - page 11
11 5. Attach a properly sized length of Selkirk Metalbestos model PS or model G venting to the exhaust vent adapter using the inner vee bands, see Figures 7 and 7B on page 10. 6. Fill the grooves in both inner vee bands with high-temp silicone sealant, Dow Corning 736 or equivalent. 7. Position the inner vee bands around the inner pipe flanges and ...
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State Industries GPV-540A - page 12
12 T ABLE 9A MAXIMUM CAP ACITY OF PIPE IN CUBIC FEET OF GAS PER HOUR (Based upon a Pressure Drop of 0.5 inch Water Column and 0.5 Specific Gravity Gas and max. gas press. of .5 psig) LENGTH I N Nominal Iron Pipe Sizes, Millimeters METERS 1/2" 3/4" 1" 1 1/4" 1 1/2" 2 " 2 1/2" 3" 4 " 3.0 51 105 199 410 615 ...
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State Industries GPV-540A - page 13
13 ROBERTSHA W ® 7000 DERHC GAS CONTROL V AL VE FIGURE 10. W A TER LINE CONNECTIONS Following are detailed installation diagrams for typical methods of application for the water heaters. The water heater may be installed by itself, or with a separate storage tank, on both single and two-temperature systems. When used with a separate storage tank, ...
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State Industries GPV-540A - page 14
14 INST ALLA TION DIAGRAMS ONE TEMPERA TURE - ONE HEA TER VERTICAL STORAGE T ANK FORCED CIRCULA TION WITH OR WITHOUT BUILDING RECIRCULA TION DANGER IF BUILDING COLD W A TER SUPPL Y HAS A BACKFLOW PREVENTER, CHECK V AL VE OR W A TER METER WITH CHECK V AL VE, PROVISIONS FOR THERMAL EXP ANSION OF W A TER IN THE HOT W A TER SYSTEM MUST BE PROVIDED. NOT ...
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State Industries GPV-540A - page 15
15 TWO TEMPERA TURE - ONE HEA TER HIGH TEMPERA TURE WITH OR WITHOUT BUILDING RECIRCULA TION TWO TEMPERA TURE - TWO HEA TERS HIGH TEMPERA TURE WITH OR WITHOUT BUILDING RECIRCULA TION *PIPE RELIEF V AL VE TO OPEN DRAIN NOTE: IF TEMPERED WA TER IS RECIRCULA TED, RETURN LINE SHOULD BE CONNECTED A T POINT “A”. INSTA LL IN ACCORDANCE WITH LOCAL CODES ...
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State Industries GPV-540A - page 16
16 CAUTION: IF BUILDING COLD W A TER SUPPL Y HAS A BACKFLOW PREVENTER, CHECK V ALVE OR W A TER METER WITH CHECK V AL VE, PROVISIONS FOR THERMAL EXP ANSION OF W A TER IN THE HOT W A TER SYSTEM MUST BE PROVIDED. TWO TEMPERA TURE - THREE HEA TERS (TWO PRE-HEA TERS/ONE BOOSTER) WITH OR WITHOUT BUILDING RECIRCULA TION TWO TEMPERA TURE - TWO HEA TERS (ON ...
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State Industries GPV-540A - page 17
17 TWO TEMPERA TURE - ONE HEA TER HIGH TEMPERA TURE WITH RECIRCULA TION OF SANITIZING LOOP CAUTION: IF BUILDING COLD W A TER SUPPL Y HAS A BACKFLOW PREVENTER, CHECK V AL VE OR WA TER METER WITH CHECK V AL VE, PROVISIONS FOR THERMAL EXP ANSION OF W ATER IN THE HOT WA TER SYSTEM MUST BE PROVIDED. DANGER TEMPERA TURE SETTING SHOULD NOT EXCEED SAFE TEM ...
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State Industries GPV-540A - page 18
18 MANIFOLD KITS Precision cut type “L” all copper State manifold kits assure water flow balance of all units. Without this balance, the full water heating and storage potential of the system cannot be achieved. Plus, the units with the higher water flow may have a shortened life. Unions shown in piping diagrams are not included in the manifold ...
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State Industries GPV-540A - page 19
19 HEA TER WIRING IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED, IT MUST BE REPLACED WITH 105°C WIRE OR ITS EQUIV ALENT , EXCEPT IN THE BURNER HOUSING USE 200°C WIRE. The power burner is wired to the heater as shown in Figure 1 1 for GPG models and Figure 12 for GPV models. The model and rating plate provided the ele ...
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State Industries GPV-540A - page 20
20 FIGURE 1 1. ...
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State Industries GPV-540A - page 21
21 FIGURE 12. ...
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State Industries GPV-540A - page 22
22 FOR YOUR SAFETY READ BEFORE LIGHTING 1 . Remove thermostat control cover . 2 . Set thermostat to lowest setting. 3 . Turn burner switch to “OFF”. W ARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance is equipped with an ignition de ...
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State Industries GPV-540A - page 23
23 SEQUENCE OF OPERA TION – Power on. – Heater in standby mode. – Thermostat calls for heat. – Blower motor starts. – Blower operation closes the normally open blower prover/ blocked outlet safety pressure switch. – On proof of airflow , Honeywell S8680J flame control module energized. – 45 seconds prepurge cycle begins. – Following ...
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State Industries GPV-540A - page 24
24 1. Check gas line pressure with a manometer . Set initial gas line pressure at 9-10” w .c. before turning the heater “ON”. Read gas line pressure and gas manifold pressure when the heater main gas is “ON”. Adjust gas line regulator setting if the gas line pressure drops below 8” w .c. when heater main gas is “ON”. Check heater ga ...
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State Industries GPV-540A - page 25
25 PREMIX LOW NOx BURNER - EXPLODED VIEW FOR GPG MODELS FIGURE 13. ...
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State Industries GPV-540A - page 26
26 PREMIX LOW NOx BURNER - EXPLODED VIEW FOR GPV MODELS FIGURE 14. ...
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State Industries GPV-540A - page 27
27 GENERAL INFORMA TION POWER BURNER The initial start-up procedure of the gas power burner is provided on page 18 thru 21. Refer to Figure 12, burner exploded view for burner components location. The sequence of operation of the power burner is provided on page 15. For detailed Power Burner Operation, Maintenance and Troubleshooting refer to the s ...
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State Industries GPV-540A - page 28
28 DRAINING The heater must be drained if it is to be shut down and exposed to freezing temperatures. Maintenance and service procedures may also require draining the heater . 1. Turn off the heater electrical disconnect switch. 2. Close the cold water inlet valve to heater . 3. Open a nearby hot water faucet to vent the system. 4. Open the heater ...
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State Industries GPV-540A - page 29
29 ABOVE ALL, DO NOT PLUG THE TEMPERA TURE AND PRESSURE RELIEF V AL VE. THIS IS NOT A SOLUTION AND CAN CREA TE A HAZARDOUS SITUA TION. CIRCULA TING PUMP The water heating system may include a circulating pump. Where used, it should be lubricated as directed by the circulator manufacturer . LOW EMISSION POWER BURNER KEEP THE AREA AROUND THE BURNER C ...
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State Industries GPV-540A - page 30
30 2. Check the fuses. • The electrical disconnect switch usually contains fuses. 3. The capacity of the heater may have been exceeded by a large demand for hot water . 4. Colder incoming water temperature will lengthen the time required to heat water to the desired temperature. • If the heater was installed when incoming water temperature was ...
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State Industries GPV-540A - page 31
31 and the troubleshooting section of burner manual before continuing. Make sure the appliance is connected to a 120 V ac power supply , burner switch is “ON” and manual gas valve is in the “ON” position, and all electrical connections are secure before continuing to troubleshoot this appliance. MOTOR WILL NOT RUN 1. Confirm 120 V ac. Also, ...
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State Industries GPV-540A - page 32
32 5. As soon as the pilot gas valve is energized, check for the burner pilot flame through the burner peek-hole. If the pilot flame is established inside the burner , then proceed to Step 6. • Turn the burner switch to “OFF” position for at least one minute to reset the heater . • Check for 24V between “PV” terminal and “MV/PV” ter ...
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State Industries GPV-540A - page 33
33 Model GPG/GPV Limited W arranty S t ate Industries, Inc. , the warrantor , extends the following LIMITED W ARRANTY to the owner of this water heater . 1. THE T ANK If the glass-lined tank in this water heater shall prove upon examination by the warrantor to have leaked due to the natural corrosion from potable water therein, during the first THR ...
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State Industries GPV-540A - page 34
34 COMMERCIAL TANK TYPE WATER HEATER REPLACEMENT PARTS LIST MODELS GPG/GPV-540A THRU 740A SERIES 104 STATE WATER HEATERS 500 Lindahl Parkway, Ashland City, TN 37015 Phone: 1-800-821-2017 • Fax: 1-800-6449306 website: www.statewaterheaters.com GPV VENT KIT 9 CLEANOUT ASSEMBL Y 11 C 11 B 11 A 11 4 BAROMETRIC DRAFT CONTROL RELIEF VA LV E 12 9B 9A (P ...
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State Industries GPV-540A - page 35
35 GPG GPV Item Description GPG-540A GPG-650A GPG-740A 1 ........ Anode, Plug ........................................................................ 183523-48(4) ............... 183523-48(4) ................ 83523-48(4) 2 ........ Baffle, Flue ........................................................................... 194974(16) ................. ...
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State Industries GPV-540A - page 36
36 GPG BURNER ASSEMBL Y (Part numbers are listed on page 37) ...
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State Industries GPV-540A - page 37
37 GPG GPG GPG GPG Item Description GPG-540A GPG-650A GPG-740A 1 ....... Ignition Control . .. .. .. .. .. . .. .. .. .. .. ............................................................ 6207 ............................. 6207 ............................ 6207 2 ....... Motor - 1/4 HP 3450 RPM ......................................................... ...
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State Industries GPV-540A - page 38
38 GPV BURNER ASSEMBL Y (Part numbers are listed on page 39) ...
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State Industries GPV-540A - page 39
39 GPV GPV GPV GPV Item Description GPV-540A GPV-650A GPV-740A 1 ....... Ignition Control . .. .. .. .. .. . .. .. .. .. .............................................................. 6207 ............................. 6207 ............................ 6 20 7 2 ....... Motor - 1/4 HP 3450 RPM ........................................................ ...
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State Industries GPV-540A - page 40
40 500 Lindahl Parkway , Ashland City , TN 37015 Phone: 800-821-2017 Fax: 800-644-9306 www.statewaterheaters.com ...
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