Instruction Manual commercial gas water heaters MODELS GPG 81-140 Thru 81-370 SERIES 104/105 INSTALLATION - OPERATION - SERVICE - MAINTENANCE - LIMITED WARRANTY 500 Tennessee Waltz Parkway Ashland City, TN 37015 Low Lead Content 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.
Table Of Contents Safe Installation, Use and Service ���������������������������������������� 3 Air From Other Indoor Spaces �������������������������������������������������������� 18 Approvals ������������������������������������������������������������������������������������������ 3 Vent Connection ������������������������������������������������������������������������������ 19 General Safety Information �������������������������������������������������4-5 Water Heater Installation ���������������
Safe Installation, Use and Service The proper installation, use and servicing of this water heater is extremely important to your safety and the safety of others. Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual.
General Safety Information Fire or Explosion Hazard Fire Hazard Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. For continued protection against risk of fire: Avoid all ignition sources if you smell gas. Do not expose water heater controls to excessive gas pressure. Do not install water heater on carpeted floor. Do not operate water heater if flood damaged. Use only the gas shown on the water heater rating label.
General Safety Information Read and understand this instruction manual and the safety messages herein before installing, operating or servicing this water heater. Explosion Hazard Overheated water can cause water tank explosion. Failure to follow these instructions and safety messages could result in death or serious injury. Properly sized temperature and pressure relief valve must be installed in the opening provided. This manual must remain with the water heater.
Introduction Thank You for purchasing this water heater. Properly installed and maintained, it should give you years of trouble free service. Abbreviations Used Warranty on this product 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.
FEATURES AND COMPONENTS high limit switch BAROMETRIC DRAFT CONTROL The dual bulb controller (fig. 1) 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). 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.
installation considerations Rough In Dimensions FIGURE 5. TABLE 1 . Models GPG 81-140 Thru 81-370 APPROX. SHIP. WT. MODELS A B C D E G H J (LBS.) GAS ASME IN OUT STD.
installation considerations TABLE 2. HEATER PERFORMANCE DATA GPG MODELS STORAGE CAPACITY U.S. GALLONS MODELS INPUT RATING BTU/HR. RECOVERY RATE GPH@100°F RISE RECOVERY RATE GPH@140°F RISE MAXIMUM AMPERES 120V, 60Hz, 10 GPG 81-140 81 140,000 136 97 5 GPG 81-199 81 199,000 193 138 5 GPG 81-270 81 270,000 262 187 5 GPG 81-370 81 370,000 359 256 5 Models with letter “A” following the model number have the optional ASME tank construction.
Installation Considerations locating the water heater The heater must not be located in an area where it will be subject to freezing. CAUTION Locate it near a floor drain. The heater should be located in an area where leakage from heater or connections will not result in damage to adjacent area or to lower floors of the structure. Property Damage Hazard • All water heaters eventually leak. When such locations cannot be avoided, a suitable metal drain pan should be installed under heater.
is to reduce the standby heat loss encountered with storage tank heaters. The water heaters covered by this manual meet or exceed the Energy Policy Act standards with respect to insulation and standby heat loss requirements, making an insulation blanket unnecessary. Should you choose to apply an insulation blanket to this heater, you should follow these instructions. See the Features and Components section of this manual for identification of components mentioned below.
CIRCULATING PUMP WIRING DIAGRAM DISHWASHER LOOP WITH TOGGLE SWITCH CIRCULATING PUMP WIRING DIAGRAM STORAGE TANK OR BUILDING RECIRCULATION FIELD SUPPLIED TEMPERATURE CONTROL INSTALLED IN THE STORAGE TANK OR CIRCULATING LOOP RETURN LINE DISHWASHER FIELD SUPPLIED TEMPERATURE SWITCH CIRCULATING LOOP RETURN LINE BreathingTOGGLE Hazard - Carbon Gas CONTROL Monoxide INSTALLED IN THE NOTE: USE SEPARATE 120 VAC POWER SUPPLY FOR PUMP CIRCUIT.
Installation Requirements 4. When installing multiple water heaters in the same gas supply system it is recommended that individual positive lock-up gas pressure regulators be installed at each unit. Gas supply Systems Low pressure building gas supply systems are defined as those systems that cannot under any circumstances exceed 14” W.C. (1/2 PSI Gauge). These systems do not require pressure regulation.
A properly sized thermal expansion tank must be installed on all closed systems to control the harmful effects of thermal expansion. Contact a local plumbing service agency to have a thermal expansion tank installed. HOT WATER OUTLET See Water Line Connections on page 19 and the Water Piping Diagrams beginning on page 35.
Contaminated Air No valve or other obstruction is to be placed between the Temperature-Pressure Relief Valve and the tank. Do not connect discharge piping directly to the drain unless a 6” (15.2 cm) air gap is provided. To prevent bodily injury, hazard to life, or property damage, the relief valve must be allowed to discharge water in adequate quantities should circumstances demand. If the discharge pipe is not connected to a drain or other suitable means, the water flow may cause property damage.
Unconfined Space Direct Vent Appliances An Unconfined Space is one whose volume IS NOT 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. Rooms communicating directly with the space, in which the appliances are installed, through openings not furnished with doors, are considered a part of the unconfined space.
Fresh Air Openings For Confined Spaces Alternatively a single permanent opening, commencing within 12 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.
Outdoor Air Through Two Vertical Ducts When ducts are used, they shall be of the same cross sectional area as the free area of the openings to which they connect. The minimum dimension of rectangular air ducts shall be not less than 3" (76.2 mm). The illustrations shown in this section of the manual are a reference for the openings that provide fresh air into confined spaces only. Air From Other Indoor Spaces Do not refer to these illustrations for the purpose of vent installation.
VENT CONNECTION 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 connections must be made to an adequate stack or chimney.
Tube Inlet Installation This water heater is provided with a properly rated/sized and certified combination temperature - pressure (T&P) relief valve by the manufacturer. See Temperature-Pressure Relief Valve on pages 14-15 for information on replacement and other requirements. CAUTION Water Damage Hazard Figure 17. • Temperature-Pressure Relief Valve discharge pipe must terminate at adequate drain. BURNER INSTALLATION Remove the factory-installed insulation covering the combustion chamber opening.
heater wiring All electrical work must be installed in accordance with the current edition of the National Electrical Code ANSI/NFPA No. 70 or Canadian Electrical Code CSA C22.1 and must conform to all local code authority having jurisdiction. AN ELECTRICAL GROUND IS REQUIRED TO REDUCE RISK OF ELECTRICAL SHOCK OR POSSIBLE ELECTROCUTION.
GAS PIPING Apply joint compounds (pipe dope) sparingly and only to the male threads of pipe joints. Do not apply compounds to the first two threads. Use compounds resistant to the action of liquefied petroleum gases. Contact your local gas service company to ensure that adequate gas service is available and to review applicable installation codes for your area.
START-UP and OPERATION • Attach a gas pressure gauge or manometer to upstream side of main gas cock and a gas pressure gauge or manometer to the manifold pressure tapping. • Check voltage at disconnect switch to make certain that it matches that shown on the burner label. • Apply a few drops of No. 20 SAE non-detergent oil to the motor bearings. • Drill max.
SEQUENCE OF OPERATION FLOW CHART Description of this flow chart can be found in the “SEQUENCE OF OPERATION” section found on page 25. START THERMOSTAT CALLS FOR HEAT. SAFE START CHECK POWER INTERUPTION. SYSTEM SHUTS OFF. RESTARTS WHEN POWER IS RESTORED. SAFE START CHECK IF FLAME SIMULATION CONDITION IS PRESENT, SYSTEM WILL NOT START. VALVE-ON DELAY (S89F ONLY) TRIAL FOR IGNITION BURNER OPERATION END VALVE-ON DELAY 30S PREPURGE COMBUSTION AIR BLOWER STARTS.
LIGHTING & OPERATION LABEL Figure 21.
Adjustments time required for the heater to consume 5 cubic feet of gas. The actual rate may then be estimated by using the formula below: 1. Check gas line pressure and manifold pressure (Table 9) and adjust as required. (3600/T) x H = Btuh 2. Check barometric damper for proper operation. Parts must move freely. T = Time in seconds to burn one cubic foot of gas. 3. Allow the unit to operate for 15 minutes. Drain hot water from the heater or storage tank to continue main burner operation.
SETTING BURNER OPERATION Table 9. NOMINAL START-UP SPECIFICATIONS Make combustion measurements and corresponding air shutter adjustments per Table 9. Combustion results from Table 9 are for natural gas models. MODEL GPG 81-140 GPG 81-199 GPG 81-270 GPG 81-370 Max. Gas Line Press.(W.C.) Nat. Gas - 10.5” W.C./Prop. Gas -13.0” Manifold Press. (W.C.) Natural Gas 3.5 3.5 3.5 3.5 Propane Gas 3.5 3.5 3.5 3.5 Orifice Natural Gas 0.24 0.308 0.386 0.532 Propane Gas 0.209 0.257 0.302 0.
mAINTENANCE venting system and BAROMETRIC DRAFT CONTROL heater where the thermostat senses the drop in water temperature and activates main burner operation of the water heater. 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. The damper gate must pivot freely in the ring guides. See Figure 23.
It is recommended that the water heater storage tank be drained and flushed every 6 months to reduce sediment buildup. The water heater should be drained if being shut down during freezing temperatures. See Features And Components in this manual for the location of the water heater components described below. TO DRAIN THE WATER HEATER STORAGE TANK: 1. Turn off the electrical supply to the water heater. 2.
Prepare the Water Heater To delime the water heater using the Flo-Jug method, first prepare the heater for deliming. Explosion Hazard Flammable hydrogen gases may be present. Keep all ignition sources away from faucet when turning on hot water. Do not smoke or have open flame or sparks in vicinity of heater. Do not mix UN•LIME with other chemicals. Do not allow contact with magnesium, aluminum or galvanized metals. Figure 25. Chemical Hazard deliming solvents UN•LIME is recommended for deliming.
While the water is being run through the tank, insert a stiff wire, copper tube flattened at one end or an opened wire coat hanger through the cleanout opening and scrape out any loose deposits of scale or sediment. This is an economical way to avoid unnecessary usage of the deliming solution. Normally, lime removal will be completed within one hour. Severe build-up of lime may take longer than an hour to complete descaling.
Gas Control Valve Figure 30 shows the combination gas control valves used on these heaters. If gas control valve becomes defective, repairs should not be attempted. A new valve should be installed in place of defective one. Figure 30. SERVICE ELECTRICAL SERVICING The installer may be able to observe and correct certain problems which may arise when the unit is put into operation.
Troubleshooting checklist COMPLAINT Water not hot enough. Insufficient hot water CAUSE USER REMEDY QUALIFIED SERVICE AGENCY Thermostat set too low. Set thermostat dial to a higher temperature. Upper and/or lower temperature probe out of calibration. Call qualified service agency. Thermostat set too low. Set thermostat dial to a higher temperature. Upper and/or lower temperature probe out of calibration. Call qualified service agency. Main manual gas shutoff valve partially closed.
For Your Information c. A sulfate reducing bacteria which has accumulated within the water heater (this harmless bacteria is nontoxic to humans). start up conditions SMOKE/ODOR d. An excess of active hydrogen in the tank. This is caused by the corrosion protective action of the anode rod. It is not uncommon to experience a small amount of smoke and odor during the initial start-up. This is due to burning off of oil from metal parts, and will disappear in a short while.
ALT. COLD WATER CONNECTION HOT WATER TO FIXTURES NOTES: 1. Preferred piping diagram. 2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system. 3. Service valves are shown for servicing unit. However, local codes shall govern their usage. 4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s). 5.
HOT WATER TO FIXTURES ALTERNATE LOCATION NOTES: 1. Preferred piping diagram. 2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system. 3. Service valves are shown for servicing unit. However, local codes shall govern their usage. 4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s). 5.
HOT WATER RETURN TEMPERED WATER OUTLET COLD HOT HOT WATER OUTLET NOTES: 1. Preferred piping diagram. 2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system. 3. Service valves are shown for servicing unit. However, local codes shall govern their usage. 4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
PIPE T&P TO OPEN DRAIN NOTES: 1. Preferred piping diagram. 2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system. 3. Service valves are shown for servicing unit. However, local codes shall govern their usage. 4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
PIPE T&P TO OPEN DRAIN NOTES: 1. Preferred piping diagram. 2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system. 3. Service valves are shown for servicing unit. However, local codes shall govern their usage. 4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s). 5. The water heater’s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control.
PIPE T&P TO OPEN DRAIN NOTES: 1. Preferred piping diagram. 2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system. 3. Service valves are shown for servicing unit. However, local codes shall govern their usage. 4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s). 5. The water heater’s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control.
PIPE T&P TO OPEN DRAIN HOT WATER TO FIXTURES DRAIN EXPANSION TANK COLD WATER SUPPLY TANK TEMPERATURE CONTROL CIRCULATING PUMP PRESSURE RELIEF VALVE TEMPERATURE & PRESSURE RELIEF VALVE ALTERNATE LOCATION NOTES: 1. Preferred piping diagram. 2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system. 3. Service valves are shown for servicing unit. However, local codes shall govern their usage. 4.
EXPANSION TANK COLD WATER SUPPLY HOT WATER RETURN HOT WATER TO FIXTURES PRE-HEATED WATER TO BOOSTER DRAIN BOOSTER HEATER WATER FLOW SWITCH TEMPERATURE GAGE CHECK VALVE FULL PORT BALL VALVE BOOSTER WATER RETURN TANK TEMPERATURE CONTROL CIRCULATING PUMP PRESSURE RELIEF VALVE TEMPERATURE & PRESSURE RELIEF VALVE BOOSTER WATER TO FIXTURES NOTES: 1. Preferred piping diagram. 2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system. 3.
PRE-HEATER PRE-HEATER MUST BE IDENTICAL HEATERS PIPE T&P TO OPEN DRAIN DRAIN BOOSTER RETURN (IF USED) EXPANSION TANK COLD WATER SUPPLY TANK TEMPERATURE CONTROL CIRCULATING PUMP PRESSURE RELIEF VALVE TEMPERATURE & PRESSURE RELIEF VALVE HOT OUTLET AT STORED TEMPERATURE BOOSTED WATER OUTLET TYPICAL BOOSTER HEATER PIPE T&P TO OPEN DRAIN NOTES: 1. Preferred piping diagram. 2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system. 3.
PIPE T&P TO OPEN DRAIN PIPE T&P TO OPEN DRAIN NOTES: 1. Preferred piping diagram. 2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system. 3. Service valves are shown for servicing unit. However, local codes shall govern their usage. PIPE T&P TO OPEN DRAIN HOT WATER TO FIXTURES WARNING: THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES; CHECK WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL REQUIREMENTS.
PIPE T&P TO OPEN DRAIN HEATER PIPE T&P TO OPEN DRAIN HEATER PIPE T&P TO OPEN DRAIN DRAIN TANK TEMPERATURE CONTROL CIRCULATING PUMP PRESSURE RELIEF VALVE ALT. COLD WATER CONNECTION EXPANSION TANK HOT WATER RETURN WATER FLOW SWITCH TEMPERATURE GAGE CHECK VALVE FULL PORT BALL VALVE COLD WATER SUPPLY LEGEND TEMPERATURE & PRESSURE RELIEF VALVE HOT WATER TO FIXTURES NOTES: 1. Preferred piping diagram. 2.
HEATER PIPE T&P TO OPEN DRAIN HEATER PIPE T&P TO OPEN DRAIN HEATER STORAGE TANK HOT WATER TO FIXTURES NOTES: 1. Preferred piping diagram. 2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system. 3. Service valves are shown for servicing unit. However, local codes shall govern their usage. 4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s). 5.
PIPE T&P TO OPEN DRAIN PIPE T&P TO OPEN DRAIN PIPE T&P TO OPEN DRAIN NOTES: 1. Preferred piping diagram. 2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system. 3. Service valves are shown for servicing unit. However, local codes shall govern their usage. FINISHED FLOOR HOT WATER TO FIXTURES WARNING: THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES; CHECK WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL REQUIREMENTS.
HEATER HEATER PIPE T&P TO OPEN DRAIN HEATER PIPE T&P TO OPEN DRAIN PIPE T&P TO OPEN DRAIN NOTES: 1. Preferred piping diagram. 2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system. 3. Service valves are shown for servicing unit. However, local codes shall govern their usage. 4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s). 5.
HEATER HEATER PIPE T&P TO OPEN DRAIN HEATER PIPE T&P TO OPEN DRAIN DRAIN STORAGE TANK ALTERNATE LOCATION PIPE T&P TO OPEN DRAIN TANK TEMPERATURE CONTROL CIRCULATING PUMP PRESSURE RELIEF VALVE TEMPERATURE & PRESSURE RELIEF VALVE HOT WATER TO FIXTURES NOTES: 1. Preferred piping diagram. 2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system. 3. Service valves are shown for servicing unit.
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.
COMMERCIAL GAS Glass Lined Tank Type Water Heater REPLACEMENT PARTS LIST MAIN BURNER ORIFICE CHART Natural Gas Propane Gas Burner Wayne C.S. Wayne C.S. Models Number Part No. (Decimal) Part No. (Decimal) GPG 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.
Item Description GPG 81-140 GPG 81-199 GPG 81-270 GPG 81-370 1..... Anode........................................................9003892005(2)........ 9003892005(2).......9003892005(2)...........9003892005(2) 2..... Baffle, Flue.................................................9005293205(7)........ 9005293205(7).......9005293205(7)...........9005293205(7) 3..... Barometric Draft Control w Tee Assy.........9500007199............ 9500007199............9500007200...............
notes 53
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Model GPG Limited Warranty Factory Start-Up is required for activating warranty and assuring maximum operating performance. Contact your local sales representatives or Authorized StartUp Agent to arrange a FREE Certified Start-Up. State Water Heaters, the warrantor, extends the following LIMITED WARRANTY to the owner of this water heater. 1.
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