Heatilator GCDC60, GCDC80 Installation & Operating Instructions Manual

INSTALLATION

& OPERATING INSTRUCTIONS

CALIBER DIRECT VENT

GCDC60/80 DECORATIVE GAS APPLIANCE

WARNING: If the information in this manual

is not followed exactly, a fire or explosion may
result causing property damage, personal

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injury or loss of life.

— Do not store or use gasoline or other flammable

vapors and liquids in the vicinity of this or any
other appliance.

— What to do if you smell gas

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use
any phone in your building.

• Immediately call your gas supplier from a
neighbor’s phone. Follow the gas supplier’s
instructions.

• If you cannot reach your gas supplier, call the
fire department.

— Installation and service must be performed by a

qualified installer, service agency or the gas
supplier.

Meets All HUD Requirements for Manufactured Housing Installations.

DO NOT use this appliance if any part has been under water. 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.

Read these installation instructions completely before beginning installation. Failure to follow them could cause an appliance
malfunction resulting in serious injury and/or property damage.

Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. Refer to this manual.
For assistance or additional information, consult a qualified installer, service agency or the gas supplier.

08/04 30803 Rev X 1

WARNING!

WARNING!

CALIBER DIRECT VENT INSTALLATION INSTRUCTIONS

TABLE OF CONTENTS

A. Appliance Specifications & Certifications .................................................................................................... 3

CALIBER Nomenclature .............................................................................................................................. 5

B. Location and Clearances ............................................................................................................................. 6

C. Framing ....................................................................................................................................................... 7

D. Setting the Appliance .................................................................................................................................. 7

E. Venting ........................................................................................................................................................ 8

F. Utilities ...................................................................................................................................................... 20

G. Finishing .................................................................................................................................................... 25

H. Appliance Preparation ............................................................................................................................... 26

I. Determine the Ignition ................................................................................................................................ 28

J. Lighting Instructions .................................................................................................................................. 28

K. Seasonal Checklist ................................................................................................................................... 30

L. Start-up Issues .......................................................................................................................................... 31

M. Maintenance Instructions ........................................................................................................................... 32

N. Optional Components ................................................................................................................................ 34

O. Replacement Parts .................................................................................................................................... 36

Index ......................................................................................................................................................... 39

Limited Lifetime Warranty .......................................................................................................................... 40

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Note: An arrow () found in the text and in the index signifies change in content.

WARNING!

DO NOT use this appliance if any part has been under water. 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.

SAFETY PRECAUTIONS

1. Please read these installation instructions completely before beginning installation procedures. Failure to follow

them could cause an appliance malfunction resulting in serious injury and/or property damage.

2. Always check your local building codes prior to installation. This installation must comply with all local, regional,

state and national codes and regulations.

3. Installation and repair should be done by a qualified service person. This appliance should also be inspected

annually by a qualified service person. More frequent inspections/cleaning may be required due to excessive lint

from carpeting, bedding materials, etc. It is imperative that the control compartment, burners and circulating air

passageways of the appliance be kept clean.

4. This is a vented decorative gas appliance. Do not burn wood or other material in this appliance.

5. NEVER leave children unattended when there is a fire burning in the appliance.

6. This appliance may only use the approved venting systems shown in these installation instructions. Venting must

not be connected to chimney flue servicing a solid fuel burning appliance or a gas fuel burning appliance.

7. NEVER use gasoline, gasoline-type lantern fuel, kerosene, charcoal lighter fluid, or similar liquids in this appliance.

Keep any flammable liquids a safe distance from the appliance.

8. While servicing this appliance, always shut off all electricity and gas to the appliance. This will prevent possible

electrical shock or burns. Also, make sure the appliance is completely cooled before servicing.

9. Do not use this appliance if any part has been under water. 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.

10. Be sure to provide adequate clearances around the air openings into the combustion chamber and adequate

accessibility clearances for servicing and proper operation.

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CALIBER DIRECT VENT INSTALLATION INSTRUCTIONS

A. APPLIANCE SPECIFICATIONS & CERTIFICATIONS

1. U.S. and Canada Certification

The Caliber Series Gas Appliance has been tested in accordance with the ANSI standard Z21.88-2000 in the United
States, the current CSA 2.33-2000, IR41, P4, and IR55 in Canada, and has been LISTED by Underwriters Laboratories
Inc. for installation as described in this manual. All components are UL, AGA, CGA or CSA safety certified.

2. Local Codes

This installation must conform with local codes. In the absence of local codes, comply with the National Fuel Gas
Code ANSI Z223.1-latest edition in the U.S.A., and the CAN/CGA B149, Installation Codes in Canada.

The Caliber Series gas appliance has been tested and listed for use in manufactured housing (mobile homes).
These installation instructions conform with the Manufactured Home Construction and Safety Standard, Title 24

CFR, Part 3280, or when such a standard is not applicable, the Standard for Manufactured Home Installations,
ANSI A225.1.

For assistance during installation contact your local dealer or contact Heatilator Technical Services Department,
Hearth & Home Technologies, 1915 W. Saunders Street, Mt. Pleasant, Iowa 52641, 1-800-927-6841.

HEATILATOR® is a registered trademark of Hearth & Home Technologies.

3. Glass Specifications/Certifications

Heatilator gas appliances manufactured with tempered glass may be installed in hazardous locations such as
bathtub enclosures as defined by the CPSC. The tempered glass has been tested and certified to the requirements
of ANSI Z97.1-1984 and CPSC 16 CFR 1202. (Safety Glazing Certification Council SGCC# 1595 and 1597. Architectural
Testing, Inc. Reports 02-31919.01 and 02-31917.01.)

This statement is in compliance with SPCS 16 CFR Section 1201.5 “Certification and labeling requirements”

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which refers to 15 USC 2063 stating, “…Such certificate shall accompany the product or shall otherwise be furnished
to any distributor or retailer to whom the product is delivered.”

Some local building codes require the use of tempered glass with permanent marking in such locations. Glass
meeting this requirement is available from the factory. Please contact your dealer or distributor to order.

WARNING!

This appliance is tested and listed for use only with the optional accessories listed in these
instructions. Use of optional accessories not specifically tested for this appliance could
void the warranty and/or result in a safety hazard.

Note: Minimum and maximum clearances must be

maintained at all times. Illustrations throughout these
instructions reflect typical installations and are for de­sign purposes only. Actual installation may vary slightly
due to individual design preferences.

The illustrations and diagrams used throughout these
installation instructions are not drawn to scale.

Tools and building supplies normally required
for installation:

Saw Framing material
Pliers Appliance surround
Hammer Caulking material
Phillips screwdriver Gloves
Tape measure Framing square
Plumb line Electric drill and bits
Level Wall-finishing
Safety glasses materials
Non-corrosive leak-check solution

08/04 30803 Rev X 3

CALIBER DIRECT VENT INSTALLATION INSTRUCTIONS

Typical Vertical Installations

(Rear and Top Vent Shown)

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Typical Horizontal Installations

(Rear and Top Vent Shown)

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CALIBER DIRECT VENT INSTALLATION INSTRUCTIONS

CALIBER NOMENCLATURE

Catalog # Descriptio n

GCDC60 41 in. width, 36 in. opening, Standing Pilot - Natural Gas Application

GCDC80 47 in. width, 42 in. opening, Standing Pilot - Natural Gas Application

The following suffixes are defined as follows:

No suffix Natural Gas, Standi ng Pilot

L Propane Gas, Standing Pilot

I Natural Gas, Intermittent Pilot

IL Propane Gas, Intermittent Pilot

R Refractory

F Fan

Examples: GCDC60IL is a Propane Gas, Intermittent Pilot Appliance

GCDC60IF is a Natural Gas, Intermittent Pilot Appliance

Components Description

DRC-RADIUS Cap Shield

COOL-ADDM Cap Shield - pack of six

DV P-TV Vertical Termination Cap

DVP45 45-deg Elbow

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DVP90 90-deg Elbow (for Heatilator appliances only)

DVP90ST 90-deg Starter Elbow (should be the first 90-deg elbow used)

RF6M Roof Flashing (vertical termination for 0/12 to 6/12 pitch) - pack of four

RF12M Steep Pitch Roof Flashing (for 7/12 to 12/12 pitch) - pack of six

DVP4 4 in. length Vent Pipe

DV P6 6 in. length Vent Pi pe

DV P 12 1 2 in. le ngth Vent P ipe

DVP24 24 in. length Vent Pipe

DVP36 36 in. length Vent Pipe

DVP48 48 in. length Vent Pipe

DVP6A 3-6 in. Slip Section Vent Pipe (to be used with another piece of pipe)

DVP12A 3-12 in. Slip Section Vent Pipe (to be used with another piece of pipe)

DVP12MI 12 i n. Vent Pipe - non-unitized (c an be c ut to leng th)

DVP24MI 24 in. Vent Pipe - non-unitized (can be cut to length)

DVP-HVS Vent Support

DVP -WS Wall S hield to ensure horizontal clearance s

DVP-FS Firestop Spacer

DVP-TRAP1 Horizontal Termination Cap with 1-3/4 in. telescoping flue and wall shield with heat shield

DVP-TRAP2 Horizontal Termination Cap with 4 in. telescoping flue and wall shield with heat shield

DVP-TB1 Basement Horizontal Termination Cap

DVP-TRAPK1 Top Vent Horizontal Kit with DVP-TRAP1 Termination Cap, wall shield with heat shield, and starter elbow

DVP-TRAPK2 Top Vent Horizontal Kit with DVP-TRAP2 Termination Cap, wall shield with heat shield, and starter elbow

DVP-HSM Extended Heat Shield

BEK Brick E xte nsion Ki t

DVP-AS Attic Insulation Shield

08/04 30803 Rev X 5

B. LOCATION AND CLEARANCES

Model A B C

60 Series 36 in. 41 in. 24-1/2 in.

80 Series 42 in. 47 in. 30-1/2 in.

CALIBER DIRECT VENT INSTALLATION INSTRUCTIONS

Dimensions

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Due to high temperatures, the appliance should be located out of traffic and away from furniture and draperies.

1. Appliance Locations and Space

Requirements

Figure 1 illustrates a variety of ways the appliance

may be located in a room. The CALIBER Series may

be installed directly on the floor or raised on a hearth.

These appliances are certified for installation in a

bedroom, bed/sitting room, or in mobile homes in the

U.S. and Canada.

WARNING!

2. Clearances

Figure 2 shows all clearances that must be
maintained around the appliance. See pages 12 &
18 for pipe clearances and pages 16, 17 & 20 for
termination cap clearances.

Figure 1 - Appliance Locations

6 30803 Rev X 08/04

Figure 2

Appliance Clearances to Combustible Materials

CAUTION:

Do not expose the appliance to the elements (such
as rain, etc.).

CALIBER DIRECT VENT INSTALLATION INSTRUCTIONS

C. FRAMING

Figure 3 shows typical framing of this appliance using combustible materials. Figure 4 shows the minimum mantel
heights. All required clearances to combustibles must be adhered to.

Figure 4 - Mantel Heights

CAUTION:

Wear gloves and safety glasses for protection.

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Figure 3 - Framing

WARNING!

To prevent contact with sagging or loose insulation, the appliance must NOT be installed against vapor barriers or
exposed insulation. Localized overheating could occur and a fire could result.

Provide adequate accessibility clearances around
the upper and lower grilles for servicing and proper
operation.

D. SETTING THE APPLIANCE

This appliance may be placed on a smooth, combustible or noncombustible continuous, flat surface. When the appliance
is installed directly on carpeting, tile or other combustible material other than wood flooring, the appliance shall be
installed on a metal or wood panel extending the full width and depth of the appliance. Slide the appliance into position
and level the from side-to-side and front-to-back. Shim with noncombustible material as necessary.

Secure the appliance by bending out the nailing flanges on each side of the appliance and nail to framing. The nailing
flanges have been positioned 5/8 in. back from the front of the appliance to allow the addition of drywall.

CAUTION:

This appliance may only use the approved venting systems shown in these Installation Instructions. It must not
be connected to a chimney flue servicing a separate solid fuel or gas fuel burning appliance.

08/04 30803 Rev X 7

WARNING!

CALIBER DIRECT VENT INSTALLATION INSTRUCTIONS

E. VENTING

1. Conversion from Top Vent to Rear Vent

a. Remove the screw holding the heat shield cover

plate to the top of the appliance and set aside.
See Figure 5.

Note: If the appliance is to be top vented discard this

plate and replace the screw you removed. If the
appliance is to be rear vented, continue to Step b.

d. Remove the four screws holding the outer collar

to the appliance top. See Figure 8. Remove the
outer collar.

Figure 5 - Insulated Cover Plate, Top of Appliance

b. Remove the three remaining screws holding the

plate surrounding the flue. See Figure 6. Remove
the plate and set aside.

Figure 8 - Remove Four Screws from Outer Collar

e. Remove the four screws holding the inner collar

to the appliance top. See Figure 9. Remove the
inner collar.

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Figure 9 - Remove Screws from Inner Collar

Figure 6 - Remove Plate Screws

c. Remove the four screws holding the inner plate

surrounding the flue. See Figure 7. Remove the
inner plate and discard.

f. Remove the four screws holding the outer shell

cover. See Figure 10. Remove the outer shell cover
and set aside.

Figure 7 - Inner Plate, Top of Appliance

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Figure 10 - Outer Shell Cover

CALIBER DIRECT VENT INSTALLATION INSTRUCTIONS

g. Remove the four screws holding the outer cover

plate to the appliance back. See Figure 11.
Remove the outer cover.

Figure 11 - Remove Outer Cover Plate

h. Remove the four screws holding the inner cover

plate to the appliance back. See Figure 12.
Remove the inner cover.

i. Place the inner collar on the appliance back and

replace the four screws that hold this collar in
place. See Figure 13.

• Make sure insulation is attached to the collar
base.

Figure 13 - Place Inner Collar on Rear of Appliance

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Figure 12 - Remove Inner Cover Plate

j. Place the outer collar on the rear of the appliance

and replace the four screws that hold this collar
in place. See Figure 14.

• Make sure insulation is attached to the collar
base.

Figure 14 - Place Outer Collar on Rear of Appliance

08/04 30803 Rev X 9

CALIBER DIRECT VENT INSTALLATION INSTRUCTIONS

k. Locate the plate removed in Step b. Place the

plate around the rear vented collars and replace
the four screws that hold the plate in place. See
Figure 15.

Figure 15 - Place Insulated Plate on Rear of Appliance

l. Place the inner cover plate on the appliance top

and replace the four screws that hold the inner

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cover plate in place. See Figure 16.

• Make sure insulation is replaced with the
cover plate.

m. Place the outer cover plate on the appliance top

and replace the four screws that hold the outer
cover plate in place. See Figure 17.

• Make sure insulation is replaced with the
cover plate.

Figure 17 - Place Outer Cover Place on Top of

Appliance

n. Locate the heat shield cover plate that was

removed in Step a. Place the cover plate on top of
the heat shield. Replace the four screws that hold
this plate in place. See Figure 18.

Figure 16 - Place Inner Cover Plate on Top of Appliance

10 30803 Rev X 08/04

Figure 18 - Place Heat Shield Cover Plate on Top of

Heat Shield

CALIBER DIRECT VENT INSTALLATION INSTRUCTIONS

o. Locate the outer shell cover that was removed in

Step f. Place the cover on top of the appliance.
See Figure 19. Replace the four screws that hold
this plate in place. See Figure 20.

Figure 19 - Place Cover Plate on Top of the Appliance

p. The appliance should look like the one shown in

Figure 21 after it has been converted to a rear
vent appliance.

Figure 21 - Completed Conversion

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Figure 20 - Screw Cover Plate into Place

08/04 30803 Rev X 11

CALIBER DIRECT VENT INSTALLATION INSTRUCTIONS

• Vertical Termination - see page 18

• Horizontal Termination - see below

2. Horizontal Termination

a. Clearances

See Figures 22 and 23 for clearance information.

Provisions shall be made to provide adequate com­bustion and ventilation air.

b. Vent Lengths for Top Vent (for rear vent, see

pages 13-14)

Various venting configurations are shown in
Figures 24-27 from which maximum vent lengths
can be determined.

CAUTION:

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Figure 22

Venting Clearances to Combustible Materials

(top vent)

Figure 23

Venting Clearances to Combustible Materials

(rear vent)

Figure 24

Vent Lengths with One Elbow

(minimum vertical)

Figure 25

Vent Lengths with One Elbow

(2 ft vertical or more, 25 ft maximum)

12 30803 Rev X 08/04