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SAFE INSTALLATION, USE AND SERVICE ............................... 2

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

TABLE OF CONTENTS .............................................................. 4

INTRODUCTION ........................................................................ 4

Preparing for the New Installation ................................... 4

TYPICAL INSTALLATION ...................................................... 5-6

LOCATING THE NEW WATER HEATER ..................................... 7

Facts to Consider About Location ............................... 7-8

Insulation Blankets ........................................................... 8

Combustion Air and Ventilation for Appliances

Located in Unconfined Spaces ........................................ 8

Combustion Air and Ventilation for Appliances

Located in Confined Spaces ........................................ 8-9

INSTALLING THE WATER HEATER ......................................... 10

Water Piping .............................................................. 10-11

Temperature-Pressure Relief Valve ............................... 11

Filling the Water Heater .................................................. 12

Venting ..................................................................... 12-13

Gas Piping ................................................................ 13-14

Sediment Traps .............................................................. 14

LIGHTING & OPERATING LABEL ............................................ 15

TEMPERATURE REGULATION ................................................ 16

FOR YOUR INFORMATION ............................................... 16-17

Start Up Conditions ........................................................ 16

Draft Hood Operation ..................................................... 16

Condensate .............................................................. 16-17

Smoke/Odor .................................................................... 17

Thermal Expansion ......................................................... 17

Strange Sounds .............................................................. 17

OPERATIONAL CONDITIONS .................................................. 18

Smelly Water .................................................................. 17

“Air” in Hot Water Faucets ............................................. 17

High Temperature Shut Off System ............................... 17

PERIODIC MAINTENANCE ....................................................... 18

Venting System Inspection ............................................ 18

Burner Inspection ........................................................... 18

Burner Cleaning .............................................................. 18

Housekeeping .......................................................... 18-19

Anode Rod Inspection .................................................... 19

Temperature-Pressure Relief Valve Operation .............. 19

Draining .......................................................................... 19

Drain Valve Washer Replacement ........................... 19-20

Service ........................................................................... 20

LEAKAGE CHECKPOINTS ...................................................... 20

REPAIR PARTS ....................................................................... 21

TROUBLESHOOTING .............................................................. 22

NOTES .................................................................................... 23

WARRANTY ..................................................................... Insert

Thank You

 for purchasing this water heater.  Properly installed and

maintained, it should give you years of trouble free service.

Abbreviations Found In This Instruction Manual:

• CSA - Canadian Standards Association

• ANSI - American National Standards Institute

• NFPA - National Fire Protection Association

• ASME - American Society of Mechanical Engineers

• GAMA - Gas Appliance Manufacturer’s Association

This gas-fired water heater is design certified by CSA INTERNATIONAL
under American National Standard/CSA Standard for Gas Water Heaters
ANSI Z21.10.1 • CSA 4.1 (current edition).

PREPARING FOR THE INSTALLATION

1. Read the “General Safety” section, page 3 of this manual first and

then the entire manual carefully.  If you don’t follow the safety rules,
the water heater will not operate properly.  It could cause DEATH,
SERIOUS BODILY INJURY AND/OR PROPERTY DAMAGE.

This manual contains instructions for the installation, operation, and
maintenance of the gas-fired water heater.  It also contains warnings
throughout the manual that you must read and be aware of.  All
warnings and all instructions are essential to the proper operation
of the water heater and your safety.  Since we cannot put everything
on the first few pages, 

READ THE ENTIRE MANUAL BEFORE

ATTEMPTING TO INSTALL OR OPERATE THE WATER HEATER.

2. The installation must conform with these instructions and the local

code authority having jurisdiction. In the absence of local codes,
installations shall comply with the National Fuel Gas Code ANSI
Z223.1/NFPA 54. This publication is available from the Canadian
Standards Association, 8501 East Pleasant Valley Rd., Cleveland
Ohio 44131, or The National Fire Protection Association, 1
Batterymarch Park, Quincy, MA 02269.

3. If after reading this manual you have any questions or do not

understand any portion of the instructions, call the local gas utility or
the manufacturer whose name appears on the rating plate.

4. Carefully plan the place where you are going to put the water heater.

Correct  combustion, vent action, and vent pipe installation are very
important in preventing death from possible carbon monoxide
poisoning and fires, see Figures 1 and 2.

Examine the location to ensure the water heater complies with the
“Locating the New Water Heater” section in this manual.

5. For California installation this water heater must be braced, anchored,

or strapped to avoid falling or moving during an earthquake.  See
instructions for correct installation procedures.  Instructions may be
obtained from California Office of the State Architect, 400 P Street,
Sacramento, CA 95814.

6. Massachusetts Code requires this water heater to be installed in

accordance with Massachusetts 248-CMR 2.00: State Plumbing Code
and 248-CMR 5.00.

7. Complies with SCAQMD rule #1121 and districts having equivalent

NOx requirements.

INTRODUCTION

INTRODUCTION

INTRODUCTION

INTRODUCTION

INTRODUCTION

TTTTTABLE OF CONTENTS

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Summary of Contents for GCVL-40 200/210

Page 1: ...RATINGPLATEONTHEWATERHEATER RESIDENTIAL GAS W RESIDENTIAL GAS W RESIDENTIAL GAS W RESIDENTIAL GAS W RESIDENTIAL GAS WA A A A ATER HEA TER HEA TER HEA TER HEA TER HEATERS TERS TERS TERS TERS For Your S...

Page 2: ...rough understanding of the requirements of the National Fuel Gas Code as it relates to the installation of gas fired water heaters The qualified installer must also be familiar with the design feature...

Page 3: ...3 GENERAL SAFETY GENERAL SAFETY GENERAL SAFETY GENERAL SAFETY GENERAL SAFETY...

Page 4: ...roperly It could cause DEATH SERIOUSBODILYINJURYAND ORPROPERTYDAMAGE This manual contains instructions for the installation operation and maintenance of the gas fired water heater It also contains war...

Page 5: ...ORDANCE WITH LOCAL CODES DRIP LEG AS REQUIRED BY LOCAL CODES FIGURE1 J Drip Leg Sediment Trap K Inner Door L Outer door M Union N Inlet Water Shut off Valve O Cold Water Inlet P Inlet Dip Tube Q Tempe...

Page 6: ...to be permanently injured by hot water than others These include the elderly children the infirm or physically mentally handicapped If anyone using hot water in your home fits into one of these groups...

Page 7: ...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 pr...

Page 8: ...sulting in fire asphyxiation serious personal injury or death Do not apply insulation to the top of the water heater as this will interfere with safe operation of the draft hood Do not cover the outer...

Page 9: ...uipment in the enclosure see Figure 7 3 When communicating with the outdoors through horizontal ducts each opening shall have a minimum free area of 1 square inch per 2 000 Btu per hour 11 cm2 kW of t...

Page 10: ...domestic water purposes a tempering valve must be installed Please refer to Figure 2 for suggested piping arrangement Water supply systems may because of such events as high line pressure frequent cut...

Page 11: ...installed directly into the fitting of the water heater designed for the relief valve Position the valve downward and provide tubing so that any discharge will exit only within 6 inches 153 mm above...

Page 12: ...eplacement heater installations where using pre existing venting venting must be inspected for obstructions and if deterioration is present venting must be replaced To insure proper venting of this ga...

Page 13: ...rving all gas appliances is used also turn off the gas at each appliance Leave all gas appliances shut off until the water heater installation is complete A gas line of sufficient size must be run to...

Page 14: ...valve of the water heater can be accomplished by either of the two methods shown in Figures 12 and 13 A sediment trap shall be installed as close to the inlet of the water heater as practical at the...

Page 15: ...burner It can be located by looking through the glass view port while pressing the piezo ignitor button several times Look for a spark at the pilot location see Figure D 9 Once the pilot has been fou...

Page 16: ...ng needs can scald and permanently injure you upon contact Some people are more likely to be permanently injured by hot water than others These include the elderly children the infirm or physically me...

Page 17: ...ner area during heating and cooling periods and should be considered normal See Condensation in this section OPERATIONAL CONDITIONS SMELLYWATER In each water heater there is installed at least one ano...

Page 18: ...ection should be made of the main burner and pilot burner see Figure 16 PERIODIC MAINTENANCE PERIODIC MAINTENANCE PERIODIC MAINTENANCE PERIODIC MAINTENANCE PERIODIC MAINTENANCE You should check for so...

Page 19: ...o completely reset and continues to release water immediately close the cold water inlet to the water heater follow the draining instructions and replace the temperature pressure relief valve with a n...

Page 20: ...ooler surfaces of the tank Droplets form and drip onto the burner or run on the floor This is common at the time of start up after installation and when incoming water is cold I Water in the water hea...

Page 21: ...de Drain optional 25 Thermostat Shield optional 26 Instruction Manual 27A Nipple with Heat Trap 27B Secondary Anode with Heat Trap Not Shown Now that you have purchased this water heater should a need...

Page 22: ...ails to operate or Replace Piezo Ignitor generator malfunctions Thermocouple TCO malfunction Replace pilot assembly High ambient room temperature Contact a service agency to determine cause BURNER WIL...

Page 23: ...23 NOTES NOTES NOTES NOTES NOTES...

Page 24: ...24...

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