State Industries GPV-540A, GPG-740A, GPV-650A, GPG-540A, GPV-740A User Manual
...
MODELS GPG/GPV-540A, 650A AND 740A
COMMERCIAL GAS, GLASS-LINED, TANK-TYPE LOW NOx
WATER HEATER
• INSTALLATION • OPERATION • MAINTENANCE • LIMITED WARRANTY
PRINTED IN U.S.A. 1004
CAUTION
TEXT IN BLACK BOLD TYPE OR UNDERLINED
CONT AINS INFORMATION RELA TIVE T O YOUR
SAFETY . PLEASE READ THOROUGHL Y BEFORE
INSTALLING AND USING THIS APPLIANCE.
ASHLAND CITY , TN
www.statewaterheaters.com
PLACE THESE INSTRUCTIONS ADJACENT TO HEATER AND
NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.
PART NO. 195047-000
1
ROUGH-IN DIMENSIONS
STANDARD BAROMETRIC DRAFT CONTROL
GPG MODELS
HORIZONT AL & DIRECT VENTING
GPV MODELS
MAXIMUM TOTAL 75 EQUIVA LE N T
FEET INTAKE AND EXHAUST
ALLOWED.
ALL DIMENSIONS IN INCHES (MILLIMETERS)
Models A B C D E F G H I Conn. Ship. Wt.
GPG/GPV 80 3 / 4 73 32 1 / 4 9 6 26 1/2 93 29 1/ 2 48 1 / 2 1 * 950
540A 2,051 1,854 819 229 152 673 2,362 749 1,232 25.4 431 kg
GPG/GPV 80 3 / 4 7 3 32 1/ 4 9 8 2 6 1 /2 93 29 1/ 2 48 1 / 2 1 * 950
650A 2,051 1,854 819 229 203 673 2,362 749 1,232 25.4 431 kg
GPG/GPV 80 3 / 4 7 3 32 1/ 4 9 8 2 6 1 /2 93 29 1/ 2 48 1 / 2 1 * 950
740A 2,051 1,854 819 229 203 673 2,362 749 1,232 25.4 431 kg
*Minimum gas supply pipe is 1 1/4”, reference Table 7 for gas supply pipe size.
Storage Input Rating Recovery Rating Recovery Rating Current Draw
Capacity BTU/HR. GPH GPH 120V
Models U.S. Gals. (Litres) Nat. 100°F Rise 140°F Rise 60Hz 1 Phase
GPG/GPV-540A 85 (261) 540,000 523.6 374
GPG/GPV-650A 85 (261) 650,000 630 450
GPG/GPV-740A 85 (261) 740,000 718 512
Based on 80% thermal efficiency obtained in State engineering laboratories.
NOTE: To compensate for the effects of high altitude areas above 2000 feet, recovery ratings should be reduced approximately
4% for every 1000 feet above sea level.
Gas Approx.
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.
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.
6.0 Amps
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.
THE HEA TER IS DESIGNED TO OPERA TE ONL Y ON NA TURAL
GAS.
THESE HEATERS MUST NOT BE INSTALLED ON
COMBUSTIBLE FLOORS.
2
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
in all cases. Authorities having jurisdiction should be consulted
before installations are made.
TABLE OF CONTENTS
ROUGH-IN-DIMENSIONS ........................................................................2
FORE WORD ....................................................................................... 2,3
TABLE OF CONTENTS........................................................................... 3
GENERAL SAFETY INFORMA TION .......................................................3
Precautions ...................................................................................3
Liquid Petroleum Models................................................................3
Chemical Vapor Corrosion ........................................................ 3,4
Improper Combustion ....................................................................4
EXTENDED NON-USE PERIODS ............................................................. 4
Cathodic Protection .......................................................................4
Insulation Blankets.........................................................................4
High Altitude Installations ..............................................................4
FEATURES ............................................................................................. 4
Low Emmission Control.................................................................4
High Limit Switch (E.C.O.) ......................................................... 4,5
Dishwashing Machine Requirement .............................................5
INSTALLA TION INSTRUCTIONS .............................................................5
Required Ability .............................................................................5
Uncrating ....................................................................................... 5
Locating the Heater ................................................................... 5,6
Hard Water ....................................................................................6
Clearances ....................................................................................6
Air Requirements...........................................................................6
Venting....................................................................................... 6,7
Vertical Venting - For GPG Models ...............................................7
Horizontal (Side-wall) Venting - For GPV Models .................... 7,8
Direct Venting - For GPV Models ............................................ 9-11
Gas Piping ............................................................................. 11-12
Gas Meter Size............................................................................12
Gas Pressure Regulation ............................................................12
Gas Valves ............................................................................ 12,13
Water Line Connections..............................................................13
Thermometers .............................................................................13
Relief Valve .................................................................................13
INSTALLA TION DIAGRAMS........................................................... 14-17
Manifold Kits ................................................................................18
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 Z223.1) 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.
P AGEP AGE
Heater Wiring...............................................................................19
ST ART UP ............................................................................................ 19
Important ......................................................................................19
Filling ............................................................................................ 19
Purging.........................................................................................19
Wiring Diagram ...................................................................... 20,21
Lighting and Operating Label ......................................................22
Sequence of Operation ............................................................... 23
Water Temperature Control .........................................................23
Adjustment Procedure (Initial Start-Up) ................................ 23,24
Adjustment Procedure for Fire-Rate, Low Nox and
High Elevation (Fine-Tune) .................................................... 24-26
GENERAL INFORMATION ....................................................................27
Power Burner ..............................................................................27
Thermostat ..................................................................................27
High Limit......................................................................................27
MAINTENANCE ....................................................................................27
General ........................................................................................27
Maintenance Schedule................................................................27
Electrical Servicing ......................................................................27
Flushing .......................................................................................27
Draining........................................................................................28
Sediment Removal .......................................................................28
Lime Scale ...................................................................................28
Relief Valve ........................................................................... 28,29
Circulating Pump ..........................................................................29
Low Emission Power Burner ......................................................29
Cleaning Flues .............................................................................29
Barometric Draft Control .............................................................29
Vent System ................................................................................ 29
CHECKLIST AND SERVICE INFORMA TION ....................................29-30
TROUBLESHOOTING ..................................................................... 30-32
Replacement Parts ......................................................................32
WARRANTY ........................................................................................33
PARTS LIST.................................................................................... 34-39
GENERAL SAFETY INFORMATION
PRECAUTIONS
DO NOT USE THIS APPLIANCE IF ANY PA RT HAS BEEN UNDER
WA TER. 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.
1. EXTERNAL FIRE.
2. DAMAGE.
3. FIRING WITHOUT WA TER.
4. SOOTING.
LIQUID PETROLEUM MODELS
WARNING
Water heaters for propane or liquefied petroleum gas (LPG)
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 use it
with Liquefied Petroleum, LP gas - STOP! Immediately contact
your dealer to obtain a correct model.
CHEMICAL VAPOR CORROSION
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 ASPHYXIA TION.
Spray can propellants, cleaning solvents, refrigerator and air
conditioning refrigerants, swimming pool chemicals, calcium
3
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).
2. INSULATION BLANKETS CAN RESTRICT THE AIR FLOW
NEEDED FOR PROPER OPERA TION OF THE COMBUSTION
SYSTEM AND COULD RESULT IN FIRE, ASPHYXIATION,
SERIOUS PERSONAL INJURY OR DEATH.
WARNING
FAILURE T O FOLLOW THESE INSTRUCTIONS CAN RESULT IN
SERIOUS PERSONAL INJURY OR DEATH.
IMPROPER COMBUSTION
WARNING
ATTIC AND OR EXHAUST F ANS OPERATING ON THE PREMISES
WITH A WA TER HEATER CAN RESUL T IN CARBON MONOXIDE
POISONING AND DEATH.
OPERATION OF THESE FANS CAN PRODUCE A NEGATIVE
DRAFT IN THE AREA OF THE WATER HEA TER 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 time 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 OPERA TION.
EXTENDED NON-USE PERIODS
CATHODIC PROTECTION
CAUTION
HYDROGEN GAS CAN BE PRODUCED IN A HOT W A TER SYSTEM
SERVED BY THIS HEA TER THA T HAS NOT BEEN USED FOR A
LONG PERIOD OF TIME (GENERALL Y TWO WEEKS OR MORE).
HYDROGEN GAS IS EXTREMEL Y FLAMMABLE. T o 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.
INSULA TION BLANKETS
HIGH ALTITUDE INSTALLATIONS
Y our S tate 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. Y our authorized st art-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 1 146.2, your heater is equipped with an internal recirculation
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.
WARNING
INSULA TION BLANKET A VAILABLE T O THE GENERAL PUBLIC
FOR EXTERNAL USE ON GAS WATER HEATERS ARE NOT
APPROVED FOR USE ON YOUR ST A TE W ATER HEA TER. THE
PURPOSE OF AN INSULA TION BLANKET IS TO REDUCE THE
STANDBY HEA T LOSS ENCOUNTERED WITH STORAGE T ANK
WATER HEATER. YOUR STA TE W ATER 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 A STA TE WA TER HEATER WILL ALSO VOID
THE ST ATE W ARRANTY FOR THE FOLLOWING REASONS:
1. INSULATION BLANKETS COVER IMPORT ANT OPERA TING
INSTRUCTIONS AND SAFETY LABELS.
FIGURE 1.
4
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.
• 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
SUPPL Y , VENTING , GAS SUPPL Y AND ELECTRICAL WORK ARE
REQUIRED. NOTE: AUTHORIZED ST ART-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.
WARNING
THERE IS A RISK IN USING FUEL BURNING APPLIANCES SUCH
AS GAS WA TER HEA TERS IN ROOMS, GARAGES OR OTHER
AREAS WHERE GASOLINE, OTHER FLAMMABLE LIQUIDS OR
ENGINE DRIVEN EQUIPMENT OR VEHICLES ARE STORED,
OPERATED OR REP AIRED. FLAMMABLE V APORS ARE HEA VY
AND TRAVEL ALONG THE FLOOR AND MA Y BE IGNITED BY THE
HEATER’S IGNITER OR MAIN BURNER FLAMES CAUSING FIRE
OR EXPLOSION. SOME LOCAL CODES PERMIT OPERA TION OF
GAS APPLIANCES IF INST ALLED 18 INCHES OR MORE ABOVE
THE FLOOR. THIS MA Y REDUCE THE RISK IF LOCATION IN SUCH
AN AREA CANNOT BE AVOIDED.
THE HEA TER SHALL BE LOCATED OR PROTECTED SO IT IS
NOT SUBJECT TO PHYSICAL DAMAGE BY A MOVING VEHICLE.
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 MA TERIAL SHOULD NOT BE
STORED OR USED IN THE SAME ROOM WITH THE HEA TER.
THE HEATER MUST NOT BE LOCA TED IN AN AREA WHERE IT
WILL BE SUBJECT TO FREEZING.
LOCA TE IT NEAR A FLOOR DRAIN. THE HEA TER SHOULD BE
LOCATED IN AN AREA WHERE LEAKAGE FROM THE HEA TER
OR CONNECTIONS WILL NOT RESULT IN DAMAGE TO THE
ADJACENT AREA OR TO LOWER FLOORS OF THE
STRUCTURE.
WHEN SUCH LOCATIONS CANNOT BE A VOIDED, A SUIT ABLE
DRAIN PAN SHOULD BE INST ALLED UNDER THE HEA TER. 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 P AN 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, unanticip ated 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 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.
5
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 AL TITUDE INST ALLA TIONS section.
PROPER INSTALLA TION ON COMBUSTIBLE FLOORING
FIGURE 2.
HARD W A TER
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.
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
MA TERIALS, GASOLINE AND OTHER FLAMMABLE VAPORS AND
LIQUIDS.
DO NOT OBSTRUCT THE FLOW OF COMBUSTION OR
VENTILATING AIR.
WARNING
FOR SAFE OPERATION PROVIDE ADEQUATE AIR FOR
COMBUSTION AND VENTILA TION. AN INSUFFICIENT SUPPL Y
OF AIR WILL CAUSE RECIRCULATION OF COMBUSTION
PRODUCTS RESULTING IN AIR CONTAMINA TION THA T MA Y BE
HAZARDOUS TO LIFE. SUCH A CONDITION OFTEN WILL RESUL T
IN A YELLOW, LUMINOUS BURNER FLAME, CAUSING
CARBONING OR SOOTING OF THE COMBUSTION CHAMBER,
BURNERS AND FLUE TUBES AND CREATES A RISK OF
ASPHYXIA TION.
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 DRA WN INTO
THE ROOM THROUGH THE CHIMNEY, CAUSING POOR
COMBUSTION. SOOTING MA Y RESUL T IN SERIOUS DAMAGE
TO THE HEA TER AND RISK OF FIRE OR EXPLOSION.
UNCONFINED SP ACE
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 SP ACE
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.
PROPER INSTALLA TION CLEARANCES
FIGURE 3.
If the confined space is within a building 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 ASPHYXIA TION.
6
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, noncondensing) 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
III 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 ASSEMBL Y
A double-acting barometric draft control assembly is provided
with any unit intended for chimney venting. The purpose of this
draft control is twofold. 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 prevent s the
heater performance from being adversely affected by conditions
within the chimney.
NOTE: A NEGA TIVE DRAFT MUST BE MAINT AINED 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 ¼ 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.
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 st ack 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 outlet.
TABLE 1.
Model Flue Outlet
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.
FIGURE 4.
In venting systems where a continuous or intermittent back
(positive) draft is found to exist, the cause must be determined
and corrected. In some cases, a special vent cap may be
required.
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 III 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.
7
Refer to Table 2 for limitations of venting system design for
horizontal venting.
TABLE 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 Vent Dia. (Inches/mm) 8” (203.2)
Maximum Number 90° 4
Of Elbows 45° 8
Maximum T ot al Vent System 75
Length, Equiv. Feet/Meters (23 m)
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 INST ALLATION
This heater is a category III 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.
When calculating the equivalent length of a venting system each
90° elbow is equivalent to 10 feet (3 m) of straight pipe. 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).
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 3
Heater Terminal Rough-In
Model Model A B C D Dimensions
GPV
540A- VH-1-8” 19-7/8” 13” 10-9/16” 8-5/8” 11-1/16”
740A
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.
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.
IMPORT ANT
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.
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.
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, 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 singlewall 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.
8
FIGURE 6.
DIRECT VENTING - FOR GPV MODELS
All exhaust vent terminal, flue reducer, and int ake 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 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
Interior 6” (152.4 mm)
Exterior 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, or burner.
TABLE 5.
Dimension in GPV
Inches (mm) 540A -740A
Flue Outlet Dia. 9 (229)
Flue Reducer Dimension 9 x 8
(Supplied) (229 x 203)
Min. Exhaust Vent Dia. Inch (mm) 8 (203)
Min. Intake Vent Dia. Inch (mm) 8 (203)
Maximum Number Of 90° 4
Elbows, Intake 45° 8
Maximum Number Of 90° 4
Elbows, Exhaust 45° 8
Total Intake Vent Max. 75 (23 m)
Length, Equiv. Ft. Min. 3 (1 m)
Total Exhaust Vent Max. 75 (23 m)
Length, Equiv. Ft. Min. 6 (1.8)
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 LOCA TIONS-INTAKE
See Table 5 limitations on venting system design for direct vent
installations.
When considering locations for the intake terminal, bear in mind
that the terminal:
9
1. Shall be located not less than 12” (304.8 mm) above grade.
DIRECT VENT SYSTEM INST ALLATION
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 snow accumulates.
5. Shall be located not less than 7 feet 2.1 m) above grade
when adjacent to a public walkway.
6. Shall not be closer than 3 feet (.9144 m) from the inside
corner of an L - shaped structure.
7. 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.
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 PIPING INSIDE WALL.
REFER TO T ABLE 3 FOR THE MAXIMUM WAL L THICKNESS
“B” FOR EACH MODEL.
2. Slide hoods through openings from outside. Fasten hoods
to exterior wall with anchors and screws supplied.
3. Install cover plate and fasten to inside wall with 4 screws
4. Attach a seal ring (Selkirk Metalbestos Model SR or equivalent)
to the vent hood collar, see Figure 7.
FIGURE 7B.
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.
WARNING
PRIMERS AND CEMENTS ARE EXTREMELY FLAMMABLE, AND
MUST NOT BE STORED OR USED NEAR HEA T OR OPEN FLAME.
ALLOW ADEQUA TE CURING TIME BEFORE OPERATING HEA TER.
DRAIN V ALVE 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.
Vent Diameter S F
8” - GPV -540A, 650A & 740A 15’ 3” 7’ 6”
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:
Expansion, Vent length between
= x
5
Inches two fixed points, feet 100
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 be sealed with high-temp silicone
sealant, Dow Corning 736 or equivalent.
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 9A.
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.
T ABLE 9
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
IN Nominal Iron Pipe Sizes, Inches
FEET 1/2" 3/4" 1" 1 1/4" 1 1/2" 2" 2 1/2" 3" 4 "
10 175 360 680 1400 2100 3960 6300 11000 23000
20 120 250 485 950 1460 2750 4360 7700 15800
30 97 200 375 770 1180 2200 3520 6250 12800
40 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
70 61 125 240 490 750 1400 2250 3900 8100
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 84 160 325 500 950 1500 2650 5500
175 37 77 145 300 460 850 1370 2450 5000
200 35 72 135 280 430 800 1280 2280 4600
11
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
IN 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 1160 1845 3221 6735
6.1 35 73 142 278 428 805 1277 2255 4626
9.1 28 59 110 225 346 644 1031 1830 3748
12.2 24 50 94 193 290 556 878 1552 3192
15.2 21 44 83 170 264 492 776 1391 2840
18.3 19 40 76 155 237 445 703 1259 2577
21.3 18 37 70 143 220 410 659 1142 2372
24.4 17 35 64 135 202 381 600 1083 2196
27.4 16 32 60 126 190 357 571 1010 2108
30.5 15 30 57 117 182 337 542 952 1962
38.1 13 27 51 105 161 299 483 864 1757
45.7 12 25 47 95 146 278 439 776 1610
53.3 1 1 23 42 88 135 249 401 717 1464
61.0 10 21 40 82 126 234 375 688 1347
WARNING
THE HEATER IS NOT INTENDED FOR OPERA TION A T HIGHER
THAN 14” (3.5 kPa) WA TER COLUMN (1/2 POUND PER SQUARE
INCH) SUPPL Y GAS PRESSURE. HIGHER GAS PRESSURES
REQUIRE SUPPLEMENTAL REDUCING SERVICE REGULATION.
EXPOSURE TO HIGHER GAS SUPPL Y PRESSURE MA Y CAUSE
DAMAGE TO THE GAS CONTROLS WHICH COULD RESUL T IN
FIRE OR EXPLOSION. IF OVERPRESSURE HAS OCCURRED
SUCH AS THROUGH IMPROPER TESTING OF GAS LINES OR
EMERGENCY MALFUNCTION OF THE SUPPL Y SYSTEM, THE GAS
V ALVE MUST BE CHECKED FOR SAFE OPERA TION. MAKE SURE
THAT THE OUTSIDE VENTS ON THE SUPPL Y REGULATORS AND
THE SAFETY VENT VALVES ARE PROTECTED AGAINST
BLOCKAGE. THESE ARE P ARTS OF THE GAS SUPPL Y SYSTEM,
NOT THE HEATER. VENT BLOCKAGE MA Y OCCUR DURING ICE
STORMS.
IT IS IMPORTANT T O GUARD AGAINST GAS V AL VE FOULING
FROM CONTAMINANTS IN THE GAS W A YS. SUCH FOULING MA Y
CAUSE IMPROPER OPERATION, FIRE OR EXPLOSION.
IF COPPER SUPPLY LINES ARE USED THEY MUST BE
INTERNALL Y TINNED AND CERTIFIED FOR GAS SERVICE.
BEFORE A TT ACHING THE GAS LINE, BE SURE THA T ALL GAS
PIPE IS CLEAN ON THE INSIDE.
TO TRAP ANY DIRT OR FOREIGN MA TERIAL IN THE GAS SUPPL Y
LINE, A DIRT LEG (SOMETIMES CALLED A SEDIMENT TRAP OR
DRIP LEG) MUST BE INCORPORA TED IN THE PIPING (SEE FIG .
10) THE DIRT LEG MUST BE READIL Y ACCESSIBLE AND NOT
SUBJECT TO FREEZING CONDITIONS. INSTALL IN
ACCORDANCE WITH RECOMMENDATIONS OF SER VING GAS
SUPPLIERS. REFER TO THE NATIONAL FUEL GAS CODE.
ANY SUPPLY PRESSURE TESTING EXCEEDING
1/2 PSIG. GAS SUPPLY LINE MUST BE CAPPED WHEN
DISCONNECTED FROM THE HEATER. FOR TEST
PRESSURES OF ½ 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 VAL VE.
GAS PIPING AND DIRT LEG INST ALLA TION
FIGURE 9.
BEFORE PLACING THE HEA TER 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 MA TCHES, CANDLES, 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. (st atic 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.
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 SHUTOFF V ALVE FROM THE GAS SUPPL Y PIPING SYSTEM DURING
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 V ALVES
Figure 10 shows the gas control valve that is supplied on these
heaters.
12
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