State Industries TPX-600-2500 User Manual

MODELS TPG-140-140 thru 600-2500

INCLUDING TPX/TPO & TPD

COMMERCIAL GAS, OIL AND GAS/OIL TANK-TYPE WATER HEATERS

• INSTALLATION • OPERATION • SERVICE • MAINTENANCE • LIMITED WARRANTY

ASME

CAUTION

TEXT PRINTED OR OUTLINED IN RED CONTAINS
INFORMATION RELATIVE TO YOUR SAFETY.
PLEASE READ THOUROUGHLY BEFORE USING
APPLIANCE.

WARNING – PROPANE MODEL

Water heaters for propane gas are different from natural gas models. A natural gas heater will not function
safely on propane gas and no attempt should be made to convert a heater from natural gas to propane gas.

Propane gas must be used with great caution. It is highly explosive and heavier than air. It collects first in the
low areas making its odor difficult to detect. If propane gas is present or even suspected, do not attempt to
find the cause yourself. Ventilate the room, then call your gas supplier or service agent. Keep area clear until
a service agent has been called.

PLACE THESE INSTRUCTIONS ADJACENT TO HEATER AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE

PRINTED IN U.S.A. 1202 PART NO. 09063370T

1

FOREWORD

This manual is intended to be used in conjunction with other
literature provided with the heater. This includes power burner
and related gas control information. It is important that this manual
and the additional publications be reviewed in their entirety before
beginning any work.

The installation should be made in accordance with the regulations
of the local code authorities and utility companies, which pertain
to this type of water heating equipment.

MAKE SURE the fuel on which the heater will operate is the same

as that specified on the heater model and rating plate.

THESE HEATERS MUST NOT BE INSTALLED ON
COMBUSTIBLE FLOORS.

Instructions for periodic testing of various water heater safety
devices are included in section titled COMBUSTION

TABLE OF CONTENTS

PAGE

FOREWORD ................................................................................ 2

IDENTIFICATION ......................................................................... 2

GENERAL SAFETY INFORMATION ........................................... 3

Precautions ............................................................................. 3

Grounding Instructions ............................................................ 3

Improper Combustion .............................................................. 3

Liquid Petroleum Models ......................................................... 3

Extended Non-Use Periods (TPG Models Only) ..................... 3

Insulation Blankets .................................................................. 3

High Altitude Installations ........................................................ 3-4

FEATURES .................................................................................. 4

Water Temperature Control ..................................................... 4

INSTALLATION INSTRUCTIONS ................................................ 4

Required Ability ....................................................................... 4

Uncrating ................................................................................. 4-5

Locating the Heater ................................................................. 5

Leveling ................................................................................... 5

Clearances .............................................................................. 5

Air Requirements ..................................................................... 5-6

Thermal Expansion (Closed System) ...................................... 6

Venting .................................................................................... 6

Vent Connector........................................................................ 6

Barometric Draft Control Assembly ......................................... 6-7

Water Line Connections .......................................................... 7

Thermometers (Not Supplied) ................................................. 7

Relief Valve ............................................................................. 7

ARRANGEMENT REQUIREMENTS AND SERVICE
RECOMMENDATIONS.

In the absence of local codes, the installation must comply with
the instruction as outlined in the latest publication of ANSI booklet
NFPA-54/ANSI Z223.1

“NATIONAL ELECTRICAL CODE”, or Canadian Gas

70

“NATIONAL FUEL GAS CODE”, NFPA No.

Association booklet CAN 1-B149.1 or CAN 1-B149.2 for Canadian
Installations also be followed.

These manuals can be purchased from the American Gas
Association Laboratories, 8501 East Pleasant Valley Road,
Cleveland, OH 44131 or the National Fire Protection Association,
1 Batterymarch Park, Quincy, MA 02269-9101, or Canadian Gas
Association Laboratories, 55 Scarsdale Road, Don Mills, Ontario,
Canada M3B 2R3.

PAGE

Gas Piping ............................................................................... 7-8

Purging .................................................................................... 8

Gas Meter Size (City Gases Only) .......................................... 8

Gas Pressure Regulator .......................................................... 8

Wiring ...................................................................................... 8-11

TWO UNIT MANIFOLD INSTALLATION ..................................... 11

OPERATION ................................................................................ 11

Important ................................................................................. 11

General .................................................................................... 11

Filling ....................................................................................... 11

Combustion Air Requirements

And Service Recommendations .............................................. 11-12

MAINTENANCE ........................................................................... 12

General .................................................................................... 12

Flushing ................................................................................... 12

Draining ................................................................................... 12

Sediment Removal .................................................................. 12

Lime Scale Removal ............................................................... 12-13

Relief Valve ............................................................................. 13

Power Burner ........................................................................... 13-14

Cleaning Flues - TPO & TPD Only .......................................... 14

Vent Systems .......................................................................... 14

Barometric Draft Control ......................................................... 14

TROUBLESHOOTING ................................................................. 14-15

Replacement Parts .................................................................. 15

LIMITED WARRANTY ................................................................. 16

This manual is supplemented by the power burner manual. All information, including start-up and

maintenance relating to the burner, can be found in that manual.

IDENTIFICATION

The heater and burner mounted identification plates provide
valuable information. When ordering parts or inquiring about a
unit, be sure to include serial number, model number and type of
fuel.

2

GENERAL SAFETY

INFORMATION

PRECAUTIONS

DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN
UNDERWATER. 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.

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
VENTILATING AIR. ADEQUATE AIR FOR COMBUSTION AND
VENTILATION MUST BE PROVIDED FOR SAFE OPERATION.

LIQUID PETROLEUM MODELS

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.

1. EXTERNAL FIRE.

2. DAMAGE.

3. FIRING WITHOUT WATER.
4 SOOTING.

Heater must be protected from freezing downdrafts during
shutdown periods.

GROUNDING INSTRUCTIONS

This water heater must be grounded in accordance with the
National Electric Code and/or local codes. These must be followed
in all cases.

This water heater must be connected to a grounded metal,
permanent wiring system; or an equipment grounding conductor
must be run with the circuit conductors and connected to the
equipment grounding terminal or lead on the water heater.

CHEMICAL VAPOR CORROSION

WARNING

CORROSION OF THE FLUEWAYS AND VENT SYSTEM MAY
OCCUR IF AIR FOR COMBUSTION CONTAINS CERTAIN
CHEMICAL VAPORS WHICH BREAK DOWN INTO ACIDS AT
HIGH TEMPERATURE. SUCH CORROSION MAY RESULT IN
FAILURE AND RISK OF ASPHYXIATION.

LP gas must be used with great caution. It is highly explosive
and heavier than air. It collects first in the low areas making its
odor difficult to detect at nose level. If LP gas is present or even
suspected, do not attempt to find the cause yourself. Ventilate
the area, then call your gas supplier or service agent. Keep area
clear until a service call has been made.

The presence of LP gas may be difficult to detect. The use of a
propane gas detector is recommended.

Only trained LP professionals should conduct the required safety
checks in accordance with industry standards.

EXTENDED NON-USE PERIODS

WARNING

HYDROGEN GAS CAN BE PRODUCED IN A HOT 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 NO SMOKING OR

OPEN FLAME NEAR THE FAUCET AT THE TIME IT IS OPEN.

Spray can propellants, cleaning solvents, refrigerator and air
conditioning refrigerants, swimming pool chemicals, calcium and
sodium chloride (water softener salt), waxes, and process
chemicals and 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 not 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

WARNING

ATTIC AND/OR EXHAUST FANS OPERATING ON THE
PREMISES WITH A WATER HEATER CAN RESULT IN CARBON
MONOXIDE POISONING AND DEATH.

OPERATING OF THESE FANS CAN PRODUCE A DOWN
DRAFT IN THE AREA OF THE WATER HEATER PREVENTING
THE PRODUCTS OF COMBUSTION FROM EXHAUSTING
THROUGH THE CHIMNEY OR VENT PIPE.

INSULATION BLANKETS

Insulation blankets 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
heaters. Your State water heater meets or exceeds the ASHRAE/
IES 90.1b-1992 standards with respect to insulation and standby
loss requirements making an insulation blanket unnecessary.

WARNING

The application of an insulation blanket will void the warranty for
this water heater. Furthermore, the application of an insulation
blanket may interfere with the operation of this water heater,
possibly resulting in property damage, injury, or death.

HIGH ALTITUDE INSTALLATIONS

Your State water heater has been designed to operate at altitudes
above 2000 feet, provided that requirement was specified at the
time of order. The firing rate will be specified on the water heater
rating plate.

3

Note: Some gas utility companies derate the heating value of the
supplied gas at high elevations. Your authorized State Start-Up
Agent must adjust for actual heating valve of the gas at the time
of start-up.

FEATURES

WATER TEMPERATURE CONTROL

The water temperature is controlled by two thermostats. One
thermostat is located near the top of the tank and the other is in
the lower part of the tank. The upper thermostat must be set at
least 5°F higher than the lower thermostat. In the case where the
water heater has electronic thermostats, this differential has been
factory set and cannot be changed.

The thermostat temperature dials are accessible by opening the
control compartment cover.

WARNING

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 CHILDREN TO USE HOT WATER TAP,
OR TO DRAW THEIR OWN BATH WATER. NEVER LEAVE A
CHILD OR DISABLED PERSON UNATTENDED IN A BATHTUB
OR SHOWER.

THE WATER HEATER SHOULD BE LOCATED IN AN AREA
WHERE THE GENERAL PUBLIC DOES NOT HAVE ACCESS
TO SET TEMPERATURES.

SETTING THE WATER HEATER TEMPERATURE AT 120°F WILL
REDUCE THE RISK OF SCALDS. Some states or provinces

require settings at specific lower temperatures.

Below you will find listed the appropriate 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 20°F (11°C). If you
experience this type of use, you should consider using lower
temperature settings to reduce scald hazards.

Temperature Time to Produce 2nd & 3rd

Setting Degree Burns on Adult Skin

180°F (82°C) Nearly Instantaneous
170°F (77°C) Nearly Instantaneous
160°F (71°C) About 1/2 Second
150°F (65°C) About 1-1/2 Seconds
140°F (60°C) Less than 5 Seconds
130°F (54°C) About 30 Seconds
120°F (49°C) More than 5 Minutes

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.
licensed plumber or the local plumbing authority.

Contact a

FIGURE 1

A high limit switch interrupts the power burner operation should
the water temperature reach 200°F.

The high limit switch must be manually reset by depressing the
red button on the front of the control when water temperature
drops to about 180°F. The manual reset high limit can be found
inside the control compartment.

INSTALLATION INSTRUCTIONS

REQUIRED ABILITY

INSTALLATION OR SERVICE OF THIS WATER HEATER IS
REQUIRED TO BE PERFORMED BY AN AUTHORIZED STATE
STARTUP AGENT. PLUMBING, AIR SUPPLY, VENTING, GAS
SUPPLY AND ELECTRICAL WORK ARE REQUIRED.

UNCRATING

The heater should be moved in the crate as close as possible to
the installation site. Depending upon size, shipping weights range
from about 1,300 to 4,500 pounds.

The installer should be guided by the instructions furnished with
the heater, local codes and utility company requirements.
Preference should be given to codes and requirements where
they differ from the heater furnished instructions.

Additional publications, which should guide the installer, include:

The latest version of the
from American Gas Association Laboratories, 8501 East
Pleasant Valley Road, Cleveland, OH 44131.

In Canada – CGA No. B149 (latest version), from Canadian
Gas Association Laboratories, 55 Scarsdale Road, Don Mills,
Ontario, Canada M3B 2R3.

Code for the installation of Heat Producing Appliances (latest
version), from American Insurance Association, 85 John Street,
New York, NY 11038.

National Fuel Gas Code, ANSI Z223.1,

4

The latest version of the National Electrical Code, NFPA No.

70. In Canada refer to Canadian Electrical Code C 22.1, from
National Fire Protection Association, 1 Batterymarch Park,
Quincy, MA 02269-9101.

A clearance of 24” should be maintained from serviceable parts,
such as relief valve, power burner, thermostat and drain valve.

MINIMUM INST ALLATION CLEARANCES

LOCA TING THE HEATER

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.

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, OPERA TED OR REPAIRED. FLAMMABLE V APORS
ARE HEAVY AND TRAVEL ALONG THE FLOOR AND MAY BE
IGNITED BY THE HEATER’S IGNITION SYSTEM OR MAIN
BURNER FLAMES CAUSING FIRE OR EXPLOSION.

SOME LOCAL CODES PERMIT OPERATION OF GAS
APPLIANCES IF INST ALLED 18 INCHES OR MORE ABOVE THE
FLOOR. THIS MA Y REDUCE THE RISK IF LOCA TION IN SUCH
AN AREA CANNOT BE AVOIDED.

THE HEATER SHALL BE LOCATED OR PROTECTED SO IT IS
NOT SUBJECT TO PHYSICAL DAMAGE BY A MOVING
VEHICLE.

TPG/TPX TPO/TPD

FRONT - 18 Inches FRONT - 18 Inches

BACK - 0 Inches Back - 6 Inches

TOP - 5 Inches Top - 12 Inches

LEFT SIDE - 0 Inches LEFT SIDE - 6 Inches

RIGHT SIDE - 0 Inches RIGHT SIDE - 6 Inches

NOTE: If a chimney connector is used, the minimum clearance
from the top of the unit to the connector is 18 inches.

AIR REQUIREMENTS

WARNING

FOR SAFE OPERATION, AN AMPLE SUPPLY OF AIR MUST
BE PROVIDED FOR PROPER COMBUSTION AND
VENTILATION AIR IN ACCORDANCE WITH SECTION 5.3, AIR
FOR COMBUSTION AND VENTILATION, OF THE
FUEL GAS CODE, NFPA-54/ANSI Z223.1 OR APPLICABLE
PROVISIONS OF THE LOCAL BUILDING CODES. AN
INSUFFICIENT SUPPLY OF AIR WILL RESULT IN A YELLOW,
LUMINOUS BURNER FLAME, CAUSING CARBONING OR
SOOTING OF THE HEAT EXCHANGER AND CREA TING A RISK
OF ASPHYXIATION. DO NOT OBSTRUCT THE FLOW OF
COMBUSTION AND VENTILA TION AIR.

UNCONFINED SP ACE

NATIONAL

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 HEATER NEAR A FLOOR DRAIN. THE HEATER
SHOULD BE LOCA TED IN AN AREA WHERE LEAKAGE FROM

THE TANK 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
METAL DRAIN PAN, ADEQUATELY DRAINED, SHOULD BE
INSTALLED UNDER THE HEATER. Such pans should be
fabricated with sides at least 2” deep, with length and width at
least 2” greater than the diameter of the heater and must be piped
to an adequate drain. The pan must not restrict combustion air
flow.

This unit must be installed on a non-combustible surface.

LEVELING

The heater shall be installed level. If it is necessary to adjust the
heater, use metal shims under the channel-type skid base.

In buildings of conventional frame, brick or stone construction,
unconfined spaces may provide adequate air for combustion.

If the unconfined space is within a building of tight construction
(buildings using the following construction: weather stripping,
heavy insulation, caulking, vapor barrier, etc.), air for combustion,
ventilation and draft hood dilution 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 OF THE ENCLOSURE TOP AND ONE
IN OR WITHIN 12 INCHES OF THE ENCLOSURE BOTTOM.
Each opening shall have a free area of at least one square inch
per 1000 Btu/hr of the total input of all appliances in the enclosure,
but not less than 100 square inches.

If the confined space is within a building of tight construction, air
for combustion, ventilation and draft dilution must be obtained
from outdoors. When directly venting with the outdoors or venting
with the outdoors through vertical ducts, two permanent openings,
located in the aforementioned manner, shall be provided. Each
opening shall have a free area of not less than one square inch
per 4000 Btu/hr of the total input of all appliances in the enclosure.
If horizontal ducts are used, each opening shall have a free area
of not less than one square inch per 2000 Btu/hr of the total input
of all appliances in the enclosure.

CLEARANCES

Provide ample clearance on all sides for installation, adjustment
and replacement of burner, control components and other parts.

Where an exhaust fan is installed in the same room with the boiler,
sufficient openings for air must be provided in the walls.

UNDERSIZED OPENINGS WILL CAUSE AIR TO BE DRAWN
INTO THE ROOM THROUGH THE CHIMNEY OR OTHER

5