A.O. Smith GPVL Series Page 9 Installation And Operating Manual Download

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GET TO KNOW YOUR WATER HEATER - GAS MODELS (list referencing Figures 1-7)

TYPICAL INSTALLATION

1. Vent Termination Elbow with Rodent

Screen

2. *Vent Pipe
3.  *Vent Pipe Coupling (if required)
4.  *Vent Pipe Elbow (long radius)
5.  Blower High Limit Switch (see Figure

6. T&P Valve
7. Cold-Water Inlet Nipple/Diptube
8. Baf

e Assembly

9. * Discharge Pipe
10. Gas Control Valve/Thermostat

(Honeywell)

11. Gas Valve Electronic Control Module

And Cover (Honeywell)

12. Drain Valve
13. Outer Gas Door
14. Manifold Door Assembly (behind

outer door) (see Figures 3 & 4)

15. *Floor Drain
16. *Metal Drain Pan
17. Flammable Vapor Sensor (under

cover) (see Figure 5)

18. **Combo Heating System Return

Inlet (Optional)

19. Air Inlet Snorkel
20. **Combo Heating System Supply

Outlet (Optional)

21. Blower with Power Cord (see also

Figure 6)

22. Air Switch (inside box) (see Figure

23. Junction Box (see Figure 6)
24. Junction Box Cover (see Figure 6)
25. Air Tubing (see Figure 6)
26. Rubber Coupling (see also Figure

27. Gear Clamp (see also Figure 6)
28. Flue Collector
29. Hot-Water Outlet Nipple
30. Anode (under cap)
31. ***Control Harness
32. Flexible Manifold Tube (see Figures

3 & 4)

33. Viewport (see Figures 3 & 4)

34. Flame Sensor Rod (see Figures 3 &

35. Gas Ori

ce (see Figures 3 & 4)

36. Sheet Metal Burner (see Figures 3 &

37. Gas Manifold (see Figures 3 & 4)
38. Hot-Surface Igniter (see Figures 3 &

39. Manifold Door Gasket (see Figures 3

& 4)

40. Manifold Door (see Figures 3 & 4)
41. Two Piece Grommet With Clip (see

Figures 3 & 4)

42. *Inlet Water Shut-off Valve
43. *Gas Supply*
44. *Main Manual Gas Shut-off Valve
45. *Ground Joint Union (gas

connection)

46. *Sediment Trap/Dirt Leg
47. *Union (water connection)
48. Rating Plate
49. *Thermal Expansion Tank (required

for all closed systems)

*, **, ***, **** see notes on following

page

Front View

Rear View

Figure 1

Figure 2

45
46

Combustion

Air Inlets

Blower

Dilution Air

Inlets

Summary of Contents for GPVL Series

Page 1: ... REQUIRED POWER VENTED GAS MODELS WITH HOT SURFACE IGNITION NOT FOR USE IN MANUFACTURED MOBILE HOMES For Your Safety AN ODORANT IS ADDED TO THE GAS USED BY THIS WATER HEATER ALL TECHNICAL AND WARRANTY QUESTIONS SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS PURCHASED IF YOU ARE UNSUCCESSFUL PLEASE CONTACT THE COMPANY LISTED ON THE RATING PLATE ON THE WATER HEATER ...

Page 2: ...tion 24 Gas Piping 24 Sediment Traps Dirt Leg 25 Filling The Water Heater 26 Venting 26 Termination Clearances Sidewall Power Vent 27 Blower Assembly Installation 28 Installation Of Vent System 28 Planning The Vent System 28 High Ambient Temperature Installations 28 Polypropylene Vent Systems 29 Condensate 29 Exhaust Venting 30 Important Notes And Warnings Venting Terminations And Sizing Vent Scre...

Page 3: ... requires businesses to warn of potential exposure to such substances This product contains a chemical known to the State of California to cause cancer birth defects or other reproductive harm This appliance can cause low level exposure to some of the substances listed in the Act IMPORTANT DEFINITIONS Qualified Installer A qualified installer must have ability equivalent to a licensed tradesman in...

Page 4: ...4 www hotwater com GENERAL SAFETY ...

Page 5: ...ors 1 cannot be seen 2 are heavier than air 3 go a long way on the floor and 4 can be carried from other rooms to the the electodes by air currents Flammable Vapors FLAMMBLE DANGER Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual Install vent system in accordance with codes Do not operate water heater if flood damaged For operation above 10 10...

Page 6: ...TH SERIOUS BODILY INJURY AND OR PROPERTY DAMAGE This manual contains instructions for 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 instructions are essential to proper operation of the water heater and your safety Since 1 we cannot put everything on the first few pages READ E...

Page 7: ...t terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless upon inspection the inspector observes carbon m...

Page 8: ...ASSACHUSETTS INSTALLATION REQUIREMENTS 1 CONNECT ELECTRONICALLY CONTROLLED TIMER TO AN ALL BRONZE PUMP PUMP MUST ACTIVATE EVERY 6 HOURS FOR 60 SECONDS TURN PUMP TIMER OFF BEFORE CLOSING PIPING LOOP SHUT OFF VALVE 2 ALL WATER PIPING MUST BE INSTALLED AND INSULATED IN ACCORDANCE WITH MASSACHUSETTS CODE 248 CMR 780 CMR 3 PIPING LOOP BETWEEN WATER HEATER AND AIR HANDLER MUST BE INSTALLED IN COMPLIANCE...

Page 9: ...ure 6 24 Junction Box Cover see Figure 6 25 Air Tubing see Figure 6 26 Rubber Coupling see also Figure 6 27 Gear Clamp see also Figure 6 28 Flue Collector 29 Hot Water Outlet Nipple 30 Anode under cap 31 Control Harness 32 Flexible Manifold Tube see Figures 3 4 33 Viewport see Figures 3 4 34 Flame Sensor Rod see Figures 3 4 35 Gas Orifice see Figures 3 4 36 Sheet Metal Burner see Figures 3 4 37 Ga...

Page 10: ...ide Taps below Caution harness has 120 VAC In operation See Planning The Vent System Condensate and Blower Assembly Installation for more information REPLACEMENT PARTS AND DELIMING PRODUCTS Replacement parts and recommended delimer may be ordered through authorized servicers or distributors When ordering parts provide complete model and serial numbers see rating plate quantity and name of part des...

Page 11: ... DRAIN MASSACHUSSETTS INSTALL A VACUUM RELIEF IN COLD WATER LINE PER SECTION 19 MGL 142 Figure 8 This appliance has been design certified as complying with American National Standard CSA Standard for water heaters and certain models with side plumbing connections are considered suitable for Water Potable Heating and Space Heating Note Do not use in space heating only applications The water supply ...

Page 12: ... be installed at water heater see Figures 8 10 or at hot water taps to further reduce system water temperature Mixing valves are available at plumbing supply stores Consult a Qualified Installer or Service Agency Follow mixing valve manufacturer s instructions for installation of the valves Before changing the factory setting on the thermostat read the Operating The Temperature Control System sect...

Page 13: ...e wiring diagram for the correct electrical connections After making all electrical connections completely fill the tank with water and check all connections for leaks Open the nearest hot water faucet and let it run for 3 minutes to purge the water lines of air and sediment and to ensure complete filling of the tank The electrical power may then be turned on Verify proper operation after servicin...

Page 14: ... flame and causing a flashback In order to detect such flammable vapors before they enter the combustion chamber this water heater is equipped with a flammable vapor sensor FVS It is a chemical absorption based sensor that is connected to the gas control thermostat see Figure 14 When exposed to flammable vapors it will trigger the control to stop the flow of gas and enter the FVS lockout state Whi...

Page 15: ...ust be piped to an adequate drain The pan must have a maximum depth of 1 75 4 5cm 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 metal drain pan piped to a drain 1 2 3 4 5 6 7 However unanticipated damage can b...

Page 16: ...nce by at least 3 76mm in every direction or if the appliance is installed in an alcove or closet the entire floor must be covered by the panel Failure to heed this warning may result in a fire hazard Clearance for servicing Adequate clearance of 24 61cm for servicing this appliance should be considered before installation such as changing the anodes etc A minimum clearance of 5 5 14cm must be all...

Page 17: ...noxide Gas WARNING AIR REQUIREMENTS For safe operation an adequate supply of fresh uncontaminated air for combustion dilution and ventilation must be provided Note Contaminated or dusty air may cause build up on the blower wheel resulting in nuisance shut downs An insufficient supply of air can cause recirculation of combustion products resulting in contamination that may be hazardous to life Such...

Page 18: ... and air conditioner refrigerants swimming pool chemicals calcium and sodium chloride water softener salt waxes bleach and process chemicals are typical compounds which are potentially corrosive A ALL AIR FROM INSIDE BUILDINGS See Figure 17 The confined space shall be provided with two permanent openings communicating directly with an additional room s of sufficient volume so that the combined vol...

Page 19: ...rs and grilles will have 60 75 percent free area Louvers and grilles shall be fixed in the open position or interlocked with the equipment so that they are opened automatically during equipment operation 7 Special Conditions Created by Mechanical Exhausting or Fireplaces operation of exhaust fans ventilation systems clothes dryers or fireplaces may create conditions requiring special attention to ...

Page 20: ...r installation of valves Before changing the factory setting on thermostat read Operating The Temperature Control System section in this manual This water heater should not be connected to any heating systems or components previously used with a non potable water heating appliance All piping components connected to this unit for space heating applications should be suitable for use with potable wa...

Page 21: ...d to reduce heat loss If the local jurisdiction requires a back flow preventer in the cold water line an expansion tank of adequate size must be installed Combo Heating Systems require higher water temperatures than other applications When the system is used to supply water for Combo Heating applications a means such as mixing valve must be installed to temper the water in order to reduce scald ha...

Page 22: ...e installed on all closed systems to control the harmful effects of thermal expansion Contact a plumbing service agency or your retail supplier regarding the installation of a thermal expansion tank Note To protect against untimely corrosion of hot and cold water fittings it is recommended that di electric unions or couplings be installed on this water heater when connected to copper pipe Avoid wa...

Page 23: ... circumstances Excessive length over 30 feet 9 14m or use of more than four elbows can cause restriction and reduce the discharge capacity of the valve No valve or other obstruction is to be placed between the T P valve and the tank Do not connect discharge piping directly to the drain unless a maximum of 6 15cm air gap is provided To prevent bodily injury hazard to life or property damage the rel...

Page 24: ...r heater Locate the slit running the length of a section of pipe insulation Spread the slit open and slip the insulation over the cold water inlet pipe Apply gentle pressure along the length of the insulation to ensure that it is fully seated around the pipe Also ensure that the base of the insulation is flush with the water heater Once seated secure the insulation with duct tape electrical tape o...

Page 25: ... rinse off soapy solution and wipe dry Use joint compound or tape compatible with propane Leak test before operating heater Disconnect gas piping and shut off valve before pressure testing system Fire and Explosion Hazard WARNING Use pipe joint compound or Teflon tape marked as being resistant to the action of gases The appliance and its gas connection must be leak tested before placing the applia...

Page 26: ... the tank and the water piping Ensure any shut off valves between the heater and the faucets are the open position 4 Open the cold water supply valve to the water heater Notes The cold water supply valve must be left open when the water heater is in use Avoid water leakage when filling the tank Do not allow the insulation of the water heater to get wet as water can reduce the effectivness of the i...

Page 27: ...e 4 ft 1 2m below or to side of opening 1 foot 30cm above opening D Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 ft 61cm from the center line of the terminal 12 in 30cm K Clearance to a mechanical air supply inlet 3 ft 91cm above if within 10 ft 3m horizontally E Clearance to unventilated soffit 12 in 30cm L Clearance above paved sidewalk or ...

Page 28: ... 7 The blower discharge boot is made to accept only straight sections of 2 or 3 pipe To start off with an elbow a short section of the straight pipe must be cut and glued into the end of the elbow that will mount on the discharge boot INSTALLATION OF VENT SYSTEM Before beginning installation of piping system thoroughly read the Vent Pipe Preparation section of this manual PLANNING THE VENT SYSTEM ...

Page 29: ... polypropylene to PVC end connection is required and is available through your supplier Optional wall plates that fit the polypropylene venting are also available through your supplier Carefully inspect the entire venting system for any signs of cracks or fractures particularly at joints between elbows and other fittings and straight runs of vent pipe Check system for signs of sagging or other str...

Page 30: ...vent material Only use approved material All venting material and components must be joined with the approved primer cleaner and solvent cement Do not common vent this heater with any other appliance During operation the plastic piping will expand as it heats up and contract as it cools down This is normal for this type of venting Rigidly fastening the vent piping can cause undue stress that may r...

Page 31: ...re are supplied with a 3 3 rubber coupling to attach the venting to the blower and a 3 45 vent termination elbow Supplied with this heater are several vent termination screens see Figures 32 33 Installed in the vent termination elbow the vent screen is required to keep foreign objects rodents and small birds from entering the venting system These screens have been sized to ensure maximum energy ef...

Page 32: ...ep Long Radius Notes 1 Use long radius elbows where possible Minimum distance between 90º elbows should be 6 150mm wherever possible 2 Venting systems may use a maximum of five 5 90 elbows 3 Use proper screen termination see Figures 32 33 2 50mm 3 76mm 4 102mm 90 elbow 8 ft 2 44m 5 ft 1 52m 2 50mm 3 76mm 4 102mm 45 elbow 4 ft 1 22m 2 5 ft 0 76m Table 2 Example for calculating equivalent feet Secti...

Page 33: ...E OF CONCEALED WIRING AND PIPING INSIDE THE WALL 9 Insert the vent piping through this hole and secure into position Connect the vent pipe to the end termination elbow as shown in Figures 35 37 10 Dry fit all vent pipes elbows connectors and fittings before joining any parts with solvent cement PARTS MUST FIT WITHOUT STRESS OR BENDING OF ANY SECTION and each connection must overlap a minimum of 1 ...

Page 34: ...Do not use glue or sealant in the rubber coupling Check that there is no stress on the connection or the vent piping that may be caused by twisting or bending 6 Tighten the upper clamp so that the vent piping is firmly secured in the coupling and is gas tight Do not over tighten or cause distortion of any of the parts Ensure the bottom of the rubber coupling is firmly seated on the blower outlet a...

Page 35: ...etent consulting agency if you have any questions about the application or installation of PVC and CPVC pipe Take the time and effort to do a professional job Shortcuts will only cause you problems and delays in start up By far the majority of failures in PVC and CPVC systems are the result of shortcuts and or improper joining techniques 2 SELECTION OF MATERIALS PCV and CPVC VENTING Cutting Device...

Page 36: ...ust be squarely cut to allow for the proper interfacing of the pipe end and the fitting socket bottom This can be accomplished with a miter box saw or wheel type cutter Wheel type cutters are not generally recommended for larger diameters since they tend to flare the corner of the pipe end If this type of cutter is used the flare on the end must be completely removed Note Power saws if used should...

Page 37: ...d the inside of the fitting socket Avoid puddling Apply a second coat of cement to the pipe end Cans of cement and primer should be closed at all times when not in use to prevent evaporation of chemicals and hardening of cement They are also very flammable and should be kept away from heat or flame Fire Hazard WARNING Figure 46 F Joint assembly Working quickly insert the pipe into the fitting sock...

Page 38: ...the water piping system Located as close to gas piping and vent pipe system as possible Located indoors and in a vertical position Protected from freezing temperatures Proper clearances from combustible surfaces maintained and not installed directly on a carpeted floor Provisions made to protect the area from water damage Metal drain pan installed and piped to an adequate drain Installation area f...

Page 39: ...on 5 Do not attempt to light manually 6 Wait five 5 minutes to clear out any gas If you then smell gas STOP Follow B in the safety information above on this label If you don t smell gas go the next step 7 Turn on all electric power to the appliance 8 Set the switch on the control to the ON position 9 Turn thermostat to desired setting DANGER Hotter water increases the risk of scald injury Consult ...

Page 40: ...hese groups or if there is a local code or state law requiring certain temperature water at the hot water tap then you must take special precautions In addition to using the lowest possible temperature setting that satisfies your hot water needs a means such as a mixing valve should be used at the hot water taps used by these people or at the water heater Mixing valves are available at plumbing su...

Page 41: ...130 54 More than 30 seconds HOT 120 49 More than 5 minutes LOW 110 43 Normal shower temp VAC 70 21 N A Table 4 Note The temperatures indicated are approximates The actual temperature of the heated water may vary The Vacation Setting VAC sets the controller at approximately 70 F 21 C This setting is recommended when the water heater is not in use for a long period of time This effectively turns the...

Page 42: ...t a plumbing service agency or your retail supplier regarding the installation of a thermal expansion tank Closed water systems See Closed Water Systems section elswhere in this manual Smoke odor 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 Strange sounds Possible...

Page 43: ...any electrical appliances which are connected to the hot water system are used such as a dishwasher or washing machine If hydrogen gas is present there will probably be an unusual sound similar to air escaping through the pipe as the hot water faucet is opened There must be no smoking or open flame near the faucet at the time it is open HIGH WATER TEMPERATURE SHUT OFF SYSTEM This water heater is e...

Page 44: ...tion something is wrong Call the local gas utility to correct the problem and clean or replace the flue and venting before resuming operation of the water heater BLOWER MAINTENANCE Inspect the top of the heater and around the ventilation openings of the blower motor and the rear blower dilution air intakes for any lint and dust that may have accumulated Depending on the location of the heater sign...

Page 45: ...UPLING BLOWER FLUE COLECTOR HOOD 11 32 NUTS MOUNTING PLATE GEAR CLAMP VENT PIPE MOTOR Figure 50 7 8 9 10 11 12 13 14 BURNER OPERATION AND INSPECTION Flood damage to a water heater may not be readily visible or immediately detectable However over a period of time a flooded water heater will create dangerous conditions which can cause death serious bodily injury or property damage Contact a qualifie...

Page 46: ... all water odor problems Artificially softened water can be exceedingly corrosive because the process substitutes sodium ions for magnesium and calcium ions The use of a excessively soft water may decrease the life of the water heater tank The anode rod should be inspected after a maximum of three years and annually thereafter until the condition of the anode rod dictates its replacement Note Arti...

Page 47: ...ve discharge BURN HOT HOT DANGER It is recommended that the temperature pressure relief valve be checked to ensure it is in operating condition at least once a year When checking the temperature pressure relief valve operation make sure that 1 no one is in front of or around the outlet of the T P valve discharge line and 2 that water discharge will not cause any property damage as water may be ext...

Page 48: ...e If the water heater is going to be shut down and drained for an extended period the drain valve should be left open with hose connected allowing water to terminate to an adequate drain Close the water heater drain valve when all water in the storage tank has drained Follow instructions in the Filling the Water Heater section Turn ON the gas supply at the main gas shut off valve Follow the lighti...

Page 49: ...mall amounts of water from temperature pressure relief valve may be due to thermal expansion or high water pressure in your area E The temperature pressure relief valve may be leaking at the tank fitting F Water from a drain valve may be due to the valve being slightly opened G The drain valve may be leaking at the tank fitting H Combustion products contain water vapor which can condense on the co...

Page 50: ...bo Heating System Return Inlet Optional 19 Air Inlet Snorkel 20 Combo Heating System Supply Outlet Optional 21 Blower with Power Cord see also Figure 62 22 Air Switch inside box see Figure 62 23 Junction Box see Figure 62 24 Junction Box Cover see Figure 62 25 Air Tubing see Figure 62 26 Rubber Coupling see also Figure 62 27 Gear Clamp see also Figure 62 28 Flue Collector 29 Hot Water Outlet Nippl...

Page 51: ... 38 39 37 35 40 41 Natural gas and Propane main burner with igniter assembly for 60k to 75k Btu hr models Flare Nut Figure 60 17 Figure 61 25 23 24 22 5 26 27 21 Figure 62 Notes Natural gas models have Right hand thread Propane models have Left hand thread For Natural gas models the Flare Nut has Right hand thread For Propane models the Flare Nut has Left hand thread ...

Page 52: ...is too high Defective gas control valve thermostat 1 2 Turn temperature knob to lower setting Replace the gas control valve thermostat 1 2 SLOW HOT WATER RECOVERY Insufficient air flue blockage Low gas pressure Orifice too small Thermostat set too low Heater too small Wrong piping connection Wasted hot water Flue clogged Air inlets blocked 1 2 3 4 5 6 7 8 9 Provide ventilation to water heater Chec...

Page 53: ...e with correct orifice see rating plate Clean locate source and correct Replace gas control valve thermostat Provide fresh air ventilation 1 2 3 4 5 6 7 UNABLE TO LIGHT THE BURNER Air in gas line Pressure switch Blocked exhaust Wire connection Defective gas control valve thermostat 1 2 3 4 5 Purge the air from gas line Check the pressure switch make sure the pressure switch hose is not kinked Chec...

Page 54: ...ustion and dilution of flue temp Increase ventilation to lower room temperature Install correct orifice 1 2 3 4 RESETTING THE HEATER CONTROL Soft lockouts as diagnosed by the system error codes require the gas control to be reset To reset the control slide the ON OFF switch to the OFF position Wait for 10 seconds and move the switch back to the ON position If the problem that caused the control to...

Page 55: ...to the Trouble Shooting Guidelines to diagnose the problem before attempting corrective action See also Flammable Vapor Sensor and TCO Resettable Lockout LED Flash Sequence Control Status Short flash once every four seconds IDLE no call for heat no fault conditions Heartbeat alternates bright dim Call For Heat no fault conditions One Flash three second pause Low Flame Signal control continues to o...

Page 56: ...56 www hotwater com This page intentionally left blank May be used for notes or to record other installation information ...

Page 57: ...www hotwater com 57 This page intentionally left blank May be used for notes or to record other installation information ...

Page 58: ...filled with potable water free to circulate at all times and with the tank free of damaging water sediment or scale deposits used in a non corrosive and non contaminated atmosphere used with factory approved anode s installed in its original installation location in the United States its territories or possessions and Canada sized in accordance with proper sizing techniques for residential water h...

Page 59: ...s 500 Tennessee Waltz Parkway Ashland City TN 37015 phone 1 800 821 2017 The warrantor will only honor replacement with identical or similar water heater or parts thereof which are manufactured or distributed by the warrantor Dealer replacements are made subject to in warranty validation by warrantor PROOF OF PURCHASEAND PROOF OF INSTALLATION DATE ARE REQUIRED TO SUPPORT WARRANTY CLAIM FROM ORIGIN...

Page 60: ...500 Tennessee Waltz Parkway Ashland City TN 37015 Technical Support 800 527 1953 Parts 800 433 2545 Fax 800 644 9306 www hotwater com Copyright 2012 A O Smith Corporation All rights reserved ...

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A.O. Smith GPVL Series, Installation And Operating Manual

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