A.O. Smith 1000 Water Heater User Manual

COPPER BOILERS FOR
HYDRONIC HEATING AND
HOT WATER SUPPLY
• Installation
Instruction Manual
• Operation
GB/GW
MODELS:
1000, 1300, 1500, 1850, 2100, 2500
• Maintenance
• Limited Warranty
SERIES 200, 201
CAUTION
TEXT PRINTED OR OUTLINED IN RED CONTAINS
INFORMATION RELATIVE TO YOUR SAFETY.
PLEASE READ THOROUGHLY BEFORE INSTALLING
AND USING THIS APPLIANCE.
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WARNING: If the information in this
manual is not followed exactly, a fire or
explosion may result causing property
damage, personal injury or loss of life.
for buying this cost
efficient, high recovery unit from
A. O. Smith Water Products Co.
•
You should thoroughly read and understand this
manual before installation and/or operation of this
boiler. Please pay particular attention to the
important safety and operating instructions as well
as the WARNINGS and CAUTIONS.
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:
• Extinguish any open flame.
• 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.
•
CONTENTS
PAGE
ROUGH-IN DIMENSIONS/CAPACITIES ............. 2 - 3
FOREWORD ..................................................... 4 - 5
FEATURES/CONTROLS ................................... 5 - 6
INSTALLATION INSTRUCTIONS ................... 6 - 22
VENTING ....................................................... 8 - 14
SYSTEM INSTALLATION .............................. 15 - 19
HYDRONIC INSTALLATION .......................... 15 - 17
HOT WATER SUPPLY INSTALLATION ......... 17 - 19
GAS CONNECTIONS .................................... 20 - 21
OPERATION ................................................ 22 - 23
LIGHTING AND OPERATING ......................... 24 - 25
CONTROL SYSTEM .................................... 26 - 31
PREVENTATIVE MAINTENANCE ................ 31 - 33
TROUBLE SHOOTING .................................. 33 - 34
LIMITED WARRANTY .......................................... 35
WIRING DIAGRAM/SCHEMATIC .................. 36 - 37
Installation and service must be
performed by a qualified installer,
service agency or the gas supplier.
A DIVISION OF A. O. SMITH CORPORATION
EL PASO, TX., MC BEE, SC., RENTON, WA.,
STRATFORD-ONTARIO, VELDHOVEN-THE NETHERLANDS
PLACE THESE INSTRUCTIONS ADJACENT TO BOILER AND
NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.
PRINTED IN U.S.A. 2526 0501
www.hotwater.com
1
PART NO. 211257-000 REV. 0
ROUGH-IN DIMENSIONS
IMPORTANT!
Refer to "Installation Clearances" section of manual
(page 7) for recommended service clearances prior
to boiler placement.
TOP VIEW
LEFT SIDE
FRONT VIEW
REAR VIEW
TABLE 1: GAS AND ELECTRICAL CHARACTERISTICS
Manifold Pressure
Electrical Characteristics
Type of Gas Inches W.C. kPa
Volts/Hz
Amperes
Model
GW/GB-1000
thru 2500
NATURAL
3.5
0.87
120/60
30
GW/GB-1000
thru 2500
PROPANE
10
2.49
120/60
30
All Models - Maximum Supply Pressure: 14.0 In. W.C. (3.49 kPa)
Minimum Supply Pressure Natural Gas: 6.0 In. W.C. (1.22 kPa)
Minimum Supply Pressure Propane Gas: 11.0 In. W.C. (2.74 kPa)
Minimum Pressures must be maintained under both load and no load
(static and dynamic) conditions.
Figure 1.
TABLE 2. ROUGH - IN DIMENSIONS
A
Model
Inches
GW/GB-1000 14.1
GW/GB-1300 24.8
GW/GB-1500 30.2
GW/GB-1850 27.7
GW/GB-2100 31.0
GW/GB-2500 38.1
Model
GW/GB-1000
GW/GB-1300
GW/GB-1500
GW/GB-1850
GW/GB-2100
GW/GB-2500
B
cm
35.8
63.0
76.7
70.4
78.7
96.8
Inches
12.2
12.2
12.2
11.2
11.2
10.5
C
cm
31.0
31.0
31.0
28.4
28.4
26.7
Inches
40.3
40.3
40.3
43.0
43.0
43.0
D
cm
102.4
102.4
102.4
109.2
109.2
109.2
Input
BTU/Hr.
KW
BTU/Hr.
KW
Natural Gas Natural Gas Propane Gas Propane Gas
990,000
289.95
990,000
289.95
1,300,000
380.74
1,300,000
380.74
1,500,000
439.31
1,500,000
439.31
1,850,000
541.82
1,850,000
541.82
2,100,000
615.04
2,100,000
615.04
2,490,000
729.26
2,490,000
729.26
2
Inches
31.6
31.6
31.6
32.3
32.3
32.3
E
cm
80.3
80.3
80.3
82.0
82.0
82.0
Exhaust
Vent Diameter
Inches
cm
10
25.4
12
30.5
12
30.5
14
35.6
14
35.6
16
40.7
Inches
26.0
39.3
44.6
44.0
49.5
56.5
F
c m Inches c m
66.0
46.8
118.9
99.8
57.3
145.5
113.3
64.3
163.3
111.8
78.3
198.9
125.7
85.3
216.7
143.5
99.3
252.2
Inlet
Vent Diameter
Inches
cm
8
20.3
10
25.4
10
25.4
10
25.4
12
30.5
12
30.5
Water Conn.
Size
2 1/2 NPT
2 1/2 NPT
2 1/2 NPT
2 1/2 NPT
2 1/2 NPT
2 1/2 NPT
Gas Inlet
2 NPT
2 NPT
2 NPT
2 1/2 NPT
2 1/2 NPT
2 1/2 NPT
TABLE 3: RECOVERY CAPACITIES
Temperature Rise - Degrees °F (°C)
Input Rating
Gal/Liter 40°F
50°F
60°F
70°F
80°F 90°F 100°F 110°F 120°F 130°F
BTU/Hr. (kW)
per Hr. (22.2°) (27.7°) (33.3°) (38.8°) (44.4°) (50°) (55.5°) (61.1°) (66.7°) (72.2°)
990,000 (290.1)
LPH
9526 7620 6350 5443 4763 4234 3810 3462 3175 2930
MODEL
GW - 1000
GW - 1300
1,300,000 (380.9)
GW - 1500
1,500,000 (439.5)
GW - 1850
1,850,000 (542.0)
GW - 2100
2,100,000 (615.3)
GW - 2500
2,490,000 (729.6)
GPH
2520
2016
1680
1440
1260
1120 1008
916
840
775
LPH
12508 10006
8339
7148
6256
5560 5005
4547
4169
3848
GPH
3309
2647
2206
1891
1655
1471 1324
1203
1103
1018
LPH
14432 11548
9620
8248
7216
6415 5772
5247
4812
4442
GPH
3818
2545
2182
1909
1697 1527
1388
1273
1175
3055
LPH
17800 14239 11865 10172
8902
7912 7122
6471
5935
5477
GPH
4709
2355
2093 1884
1712
1570
1449
LPH
20204 16163 13472 11548 10104 8981 8082
7348
6736
6218
GPH
5345
2376 2138
1944
1782
1645
LPH
23958 19168 15971 13691 11979 10648 9582
8713
7987
7371
GPH
6338
2305
2113
1950
3767
3139
4276
3564
5071
4225
2691
3055
3622
2673
3169
2817 2535
TABLE 4: HEAT EXCHANGER PRESSURE DROP
GB Models-Flow, Head Loss and Temperature Rise
20 Deg. F Rise
30 Deg. F Rise
40 Deg. F Rise
GPM
GPM
GPM
MODEL
PD-FT
Head
PD-FT
Head
PD-FT
Maximum Flow Rate
GPM
Head
PD-FT
Deg. F
Head
Rise
Minimum Flow Rate
GPM
PD-FT
Deg. F
Head
Rise
GB - 1000
83.16
5.1
55.4
2.7
41.6
1.5
154
12.2
11
42
1.5
40
GB - 1300
109.2
7.2
72.8
4.2
54.6
3.2
154
14.5
14
55
3.2
40
GB - 1500
126
10.1
84
6.3
63
4.3
154
16.3
17
64
4.3
40
GB - 1850
154
18.5
103.6
10.1
77.7
6.4
154
18.5
20
78
6.4
40
GB - 2100
n/a
n/a
117.6
14.5
88.2
8.3
154
21.3
23
89
8.3
40
GB - 2500
n/a
n/a
139.4
18.5
104.6
11.6
154
23.2
28
105
11.6
40
Note: GW models (GB optional) are equipped with pumps capable of handling 50 equivalent feet
(15.2 m) of normal pipe fittings.
3
FOREWORD
PRECAUTIONS
These designs comply with the latest edition of the American
National Standards for Gas-Fired, Low-Pressure Steam and Hot
Water Boilers, ANSI Z21.13 and CGA 4.9/CGA 3.3 latest edition, as
a low pressure boiler.
IF THE UNIT IS EXPOSED TO THE FOLLOWING, DO NOT
OPERATE UNTIL ALL CORRECTIVE STEPS HAVE BEEN MADE
BY A QUALIFIED SERVICEMAN:
1.
2.
3.
4.
Detailed installation diagrams are found in this manual. These
diagrams will serve to provide the installer a reference for the
materials and methods of piping necessary. It is essential that all
water, gas piping and wiring be installed as shown on the diagrams.
You should thoroughly read and understand this manual before
installation and/or operation of this boiler.
EXPOSURE TO FIRE.
IF DAMAGED.
FIRING WITHOUT WATER.
SOOTING.
IF THE BOILER HAS BEEN EXPOSED TO FLOODING, IT MUST BE
REPLACED.
LIQUID PETROLEUM MODELS
The factory warranty will be void if the boiler(s) have been improperly
installed or operated.
Boilers for propane or liquefied petroleum gas (LPG) are different
from natural gas models. A natural gas boiler will not function
safely on LP gas and no attempt should be made to convert a
boiler from natural gas to LP gas.
In addition to these instructions, the boiler(s) shall be installed in
accordance with those installation regulations in force in the local
area where the installation is to be made. These shall be carefully
followed in all cases. Authorities having jurisdiction should be
consulted before installations are made.
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. Leave the
building, leaving doors open to ventilate, then call your gas supplier
or service agent. Keep area clear until a service call has been
made.
In the absence of local codes, the installation must comply with
the latest editions.
In the United States:
The National Fuel Gas Code, ANSI Z223.1/NFPA 54 and the National
Electric Code, NFPA 70.
At times you may not be able to smell an LP gas leak. One cause
is odor fade, which is a loss of the chemical odorant that gives LP
gas its distinctive smell. Another cause can be your physical
condition, such as having a cold or diminishing sense of smell
with age. For these reasons, the use of a propane gas detector is
recommended.
In Canada:
The installation Code CAN/CSA B149.1 and .2 (latest edition) and
the Canadian Electric Code, CSA C22.2.
These are available from the Canadian Standards Association,
8501 East Pleasant Valley Road, Cleveland, OH 44131, USA, or,
Canadian Gas Association Laboratories, 55 Scarsdale Road, Don
Mills, Ontario M3B 2R3, Canada.
IF YOU EXPERIENCE AN OUT OF GAS SITUATION, DO NOT TRY
TO RELIGHT APPLIANCES YOURSELF. Call your local service
agent. Only trained LP professionals should conduct the required
safety checks in accordance with industry standards.
GROUNDING INSTRUCTIONS
This boiler must be grounded in accordance with the National
Electrical Code and/or local codes. Boiler is polarity sensitive,
correct wiring is imperative for proper operation.
HIGH ALTITUDE INSTALLATION
WARNING
INSTALLATIONS ABOVE 4,500 FEET REQUIRE REPLACEMENT
OF THE BURNER ORIFICES IN ACCORDANCE WITH THE
NATIONAL FUEL GAS CODE (ANSI/NFPA 54). FAILURE TO
REPLACE THE ORIFICES WILL RESULT IN IMPROPER AND
INEFFICIENT OPERATION OF THE APPLIANCE, PRODUCING
CARBON MONOXIDE GAS IN EXCESS OF SAFE LIMITS, WHICH
COULD RESULT IN SERIOUS PERSONAL INJURY OR DEATH.
This boiler 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 boiler.
WARNING
YOUR BOILER IS NOT DESIGNED TO OPERATE WITH A BOILER
INLET WATER TEMPERATURE OF LESS THAN 120°F (38°C).
COLDER INLET WATER TEMPERATURE WILL RESULT IN
SIGNIFICANT CONDENSATION DEVELOPING ON THE HEAT
EXCHANGER. THIS SITUATION CAN CAUSE A CORROSIVE
ENVIRONMENT FOR THE HEAT EXCHANGER, BURNERS AND
VENTING RESULTING IN PREMATURE DAMAGE, WHICH COULD
RESULT IN SERIOUS PERSONAL INJURY OR DEATH.
GENESIS BOILERS ARE EQUIPPED WITH SELF-REGULATING
PREJET ORIFICES WHICH AUTOMATICALLY COMPENSATE FOR
HIGHER ELEVATIONS AND ADJUST THE APPLIANCE'S INPUT
RATE ACCORDINGLY, MAKING IT UNNECESSARY TO REPLACE
ORIFICES FOR HIGH ALTITUDE (UP TO 4,500 FEET ONLY.
CONSULT THE FACTORY FOR HIGHER ALTITUDES.)
FOR SYSTEMS THAT USE LARGE VOLUMES OF COLD WATER
OR SYSTEMS UTILIZING HEAVY WATER DRAWS, CONDENSATION
CAN BE PREVENTED BY USING A BYPASS LOOP.
Some utility companies derate their gas for altitude. You should
contact your gas supplier for any specific changes which may be
required in your area. Call the local gas utility to verify BTU content
of the gas supplied.
CORRECT GAS
Ratings specified by manufacturers for most boilers apply for
elevations up to 4,500 feet (1350 m). For elevations above 4,500
feet (1350 m) ratings must be reduced by a rate of 4% for each
1,000 feet (300 m) above sea level.
Make sure the gas on which the boiler will operate is the same as
that specified on the boiler rating plate. Do not install the boiler if
equipped for a different type of gas, consult your gas supplier.
4
Example: A Genesis boiler is rated at 1,300,000 Btu/hr. input at sea
level. At an altitude of 5,000 (1500m), the prejet orifices will decrease
the input rate by 20% (= 4% x 5) to a new rating of 1,040,000 Btu/hr.
(= 80% x 1,300,000 Btu/hr.) The input reduction is achieved by the
prejet orifices through self-regulation.
FLAME SENSOR
FEATURES/CONTROLS
The flame sensor acts to prove the flame has carried over from the
ignitor to the right-most burner. If no flame is sensed, the gas
valve(s) will close automatically. If no flame is sensed on three
ignition trials the boiler will lock out. Upon lockout, manually push
the ENTER/RESET button on the display panel to restart the boiler.
MULTI-STAGE FIRING AND CONTROL SYSTEM
WATER FLOW SWITCH
ALL MODELS - The control system consists of three basic
components: 1) Central Control Board 2) Ignition Control Board
and 3) Display Board. The Central Control Board and Ignition
Control Boards are located in the control box and can be accessed
through panels on the left side and top of the unit. The Display
Board is attached to the front jacket panel. The control system is a
multi-stage control capable of managing three or four ignition
stages. Three stage models include the 1000, 1300 and 1500.
Four stage models include the 1850, 2100 and 2500. Every system
will have one Central Control Board, one Display Board and either
three or four Ignition Control Boards depending on the model.
There will be one Ignition Control Board per stage.
The Water Flow Switch is installed at the boiler outlet to prevent
burner operation in the event of inadequate water flow through the
boiler. The Water Flow Switch is a single pole, normally open
switch that will close its contacts when increasing water flow rate
is encountered. This switch is factory-set, but may require field
adjustment. The contacts will open when the flow rate drops below
the adjusted setting and the gas valve(s) will close turning off the
gas to the burners.
LIMIT CONTROLS
CAUTION
LIMIT CONTROLS ARE SAFETY DEVICES AND ARE NOT TO BE
USED AS A THERMOSTAT.
The central control board contains a strip of dip switches which
allow the user to control several system variables. Table 5 shows
a summary of these options. Make sure the dip switches are in
the appropriate position for the unit's application. Consult the
Control System section of the manual for more information, see
page 26.
The GB/GW models incorporate an outlet water probe consisting
of two limit controls:
1. An adjustable automatic reset limit control, that can be set to
either 210°F (99°C) or 240°F (115°C) depending on the
application.
2. A fixed manual reset limit factory set at 250°F (121°C). If the
manual reset should open due to high temperature the gas
valves will close and the unit will go into lockout.
DIP SWITCH CONFIGURATION TABLE
SW1 OFF
A
B
C
D
E
F
G
H
ON
3 STAGE
3 TRIALS
NO IRI
GAS VALVE
INLET
SELECTION:
4 STAGE
1 TRIAL
IRI
GAS VALVE
TANK
EITHER 3 OR 4 STAGE SYSTEM
EITHER 3 OR 1
WHETHER SYSTEM IS IRI OR
STANDARD
INLET OR TANK AS
CONTROLLING PROBE
NO EXTERNAL EXTERNAL
WHETHER EXTERNAL
THERMOSTAT THERMOSTAT THERMOSTAT IS USED
OUTLET 210°F OUTLET 240°F OUTLET MAXIMUM TEMPERATURE
190°F
220°F
MAX. SET-POINT TEMPERATURE
DEGREES °F DEGREES °C
EITHER °F OR °C FOR DISPLAYED
TEMPERATURE
If lockout occurs, manually push the ENTER/RESET
push-button on the display panel to restart the boiler.
ON/OFF SWITCH
The ON/OFF switch is a single-pole, single-throw rocker switch.
The switch provides 120VAC from the line source to the boiler.
COMBUSTION AIR BLOWER
Provides air for combustion process. The blower settings are
adjustable through the use of the air shutter, however, blowers are
set at the factory and should not need adjustment.
Figure 2. Summary of Dip Switch Options.
DIFFERENTIAL PRESSURE SWITCH
TANK PROBE
The differential pressure switch ensures that a sufficient differential
exists between the air pressure in the pre-mix chamber and the
inlet of the burner for safe, low NOX combustion. The switch has
two pressure taps marked "+" (positive) and "-" (negative). Silicone
tubing is run from the positive pressure tap of the switch to a tap on
the control panel to measure the air pressure in the pre-mix
chamber. The negative pressure tap measures the pressure taken
at the burner's auxiliary tube. Connections can be seen by removing
the lower front jacket panel. It is important that this panel remain
sealed at all times while the boiler is operating.
FOR HOT WATER SUPPLY SYSTEMS (GW models), A tank probe is
supplied with each hot water supply boiler. The inlet water
temperature will default to the tank temperature on the display when
the tank probe is installed.
Note: Tank Probe must be designated as controlling probe using
Dip Switch "D" on Central Control Board before it can be used for
(GW) hot water supply applications.
"Pigtails" of field-supplied wires should be spliced to "pigtails" of
tank probe and connected to terminal block in the 24 volt junction
box. See figure 12 for the tank probe installation. Follow the
instructions for the operation and temperature setting procedures
for the tank probe (see page 29).
This differential pressure switch is normally open and closes when
the combustion blower starts.
BLOCKED FLUE PRESSURE SWITCH
The blocked flue pressure switch ensures that the flue gas vent is
clear. This pressure switch is normally closed and only opens on
the fault conditions.
FOR HOT WATER HEATING SYSTEMS (GB models) Due to the
many various types of systems and operating conditions, a tank
5
probe is not supplied with the GB models. A tank probe can be
used as an option to control loop temperature and unit staging.
Additionally, the Inlet Temperature Probe can be used as the loop
thermostat in some heating (GB) applications. These types of
controls connect to designated wires in the junction box at the rear
of the boiler. Do not operate this boiler using the internal high
limits only, you must use an operating thermostat as mentioned
above.
If any safety relief valve is replaced, the replacement valve must
comply with the latest version of the ASME Boiler and Pressure
Vessel Code, Section IV (HEATING BOILERS). Select a relief valve
with a discharge rating NOT less than the boiler input, and a set
pressure NOT exceeding the working pressure of any component
in the system.
The storage tank temperature and pressure relief valve must
comply with the applicable construction provisions of the Standard
for Relief Valves and Automatic Gas Shut-off Devices for Hot Water
Supply Systems, ANSI Z21.22 or CSA-4.4 (and latest addendums).
The valve must be of the automatic reset type and not embody a
single-use type fusible plug, cartridge or linkage.
Note: Additional 24V devices or Tank Probe must be identified
using Dip Switches on Central Control Board before they are
recognized as a part of the heating system. See table 5 and refer to
"Multi-Stage Firing and Control System" on previous page for more
information about dip switch settings.
CIRCULATING PUMP
FOR HOT WATER HEATING SYSTEMS, the boilers are shipped
with a 50 psi pressure relief valve. This relief valve is factory
installed in the water outlet header of the boiler, see figure 1.
The pump flow rate should not exceed the maximum
recommended flow rate, see table 4.
FOR HOT WATER SUPPLY SYSTEMS, the boilers are shipped
with a 125 psi pressure relief valve. This relief valve is factory
installed in the water outlet header of the boiler, see figure 1.
FOR HOT WATER SUPPLY SYSTEMS (GW models), ordered with
the circulator as an integral part of the boiler; the pump has been
lubricated at the factory, and future lubrication should be in
accordance with the motor manufacturer's instructions provided
as supplement to this manual.
This ASME-rated valve has a discharge capacity that exceeds the
maximum boiler input rating and a pressure rating that does not
exceed the maximum working pressure shown on the boiler rating
plate.
FOR HOT WATER HEATING SYSTEMS (GB models or GW models
ordered without circulator), the circulator is NOT provided and
must be field-installed.
In addition, an A.G.A. design-certified and ASME-rated temperature
and pressure (T & P) relief valve must be installed on each and
every water storage tank in the hot water supply system, see
figures 11 and 13.
LOW WATER CUTOFF (Not Supplied)
If low water protection is required by the authorities having
jurisdiction, a low water cutoff switch should be installed
next to the boiler in the outlet water line as shown in
"HYDRONIC INSTALLATION" section. The switch should receive
periodic (every six months) inspection to assure proper operation.
A low water cutoff device of the float type should be flushed every six
months.
The T & P relief valve should have a temperature rating of 210°F
(99°C), a pressure rating NOT exceeding the lowest rated working
pressure of any system component, and a discharge capacity
exceeding the total input of the water boilers supplying water to the
storage tank.
DRAIN VALVE (Not Supplied)
Locate the T & P relief valve (a) in the top of the tank, or (b) in the
side of the tank on a center line within the upper six (6) inches
(15 cm) of the top of the tank. The tapping shall be threaded in
accordance with the latest edition of the Standard for Pipe Threads,
General Purpose (inch), ANSI/ASME B1.20.1. The location of, or
intended location for, the T & P relief valve shall be readily
accessible for servicing or replacement.
Additional drain valves must be obtained and installed on each
boiler and tank for draining purposes.
SAFETY RELIEF VALVES
Your local code authority may have other specific relief valve
requirements not covered below.
INSTALLATION INSTRUCTIONS
WARNING
THE PURPOSE OF A SAFETY RELIEF VALVE IS TO AVOID
EXCESSIVE PRESSURE WHICH MAY CAUSE TANK EXPLOSION,
SYSTEM OR BOILER DAMAGE.
REQUIRED ABILITY
INSTALLATION OR SERVICE OF THIS BOILER REQUIRES ABILITY
EQUIVALENT TO THAT OF A LICENSED TRADESMAN IN THE
FIELD INVOLVED. PLUMBING, AIR SUPPLY, VENTING, GAS
SUPPLY AND ELECTRICAL WORK ARE REQUIRED.
TO AVOID WATER DAMAGE A DRAIN LINE MUST BE CONNECTED
TO A SAFETY RELIEF VALVE TO DIRECT DISCHARGE TO A SAFE
LOCATION. A DRAIN LINE MUST NOT BE REDUCED FROM THE
SIZE OF THE VALVE OUTLET AND IT MUST NOT CONTAIN ANY
VALVES BETWEEN THE BOILER AND THE RELIEF VALVE OR THE
RELIEF VALVE AND THE DRAIN EXIT. IN ADDITION, THERE
SHOULD NOT BE ANY RESTRICTIONS IN A DRAIN LINE NOR
SHOULD IT BE ROUTED THROUGH AREAS WHERE FREEZING
CONDITIONS MIGHT OCCUR. DO NOT THREAD OR CAP THE
DRAIN LINE EXIT. RESTRICTING OR BLOCKING A DRAIN LINE
WILL DEFEAT THE PURPOSE OF THE RELIEF VALVE AND MAY
CREATE AN UNSAFE CONDITION. INSTALL A DRAIN LINE WITH
A DOWNWARD SLOPE SUCH THAT IT NATURALLY DRAINS
ITSELF.
LOCATION
When installing the boiler, consideration must be given to proper
location. Location selected should be as close to the stack or
chimney as practical with adequate air supply and as centralized
with the piping system as possible. This location should also be
such that the gas ignition system components are protected from
water (dripping, spraying, etc.) during appliance operation and
service (circulator replacement, control replacement, etc.)
6
•
•
•
•
INSTALLATION CLEARANCES
THE BOILER MUST NOT BE INSTALLED ON CARPETING.
THE BOILER SHOULD NOT BE LOCATED IN AN AREA WHERE
IT WILL BE SUBJECT TO FREEZING.
THE BOILER SHOULD BE LOCATED NEAR A FLOOR DRAIN.
THE BOILER SHOULD BE LOCATED IN AN AREA WHERE
LEAKAGE FROM THE BOILER OR CONNECTIONS WILL NOT
RESULT IN DAMAGE TO THE ADJACENT AREA OR TO LOWER
FLOORS OF THE STRUCTURE.
Sufficient area should be provided at the front and sides of the
unit for proper servicing. For ease of service, minimum
clearances of 24" (61.0 cm) in the front and 18" (46.0 cm) on
the sides are recommended. It is important that the minimum
clearances be observed to allow service to the control box and
other controls. Observing proper clearances will allow service
to be performed without movement or removal of the boiler from
its installed location. Failure to observe minimum clearances
may require removal of the boiler in order to service such items as
the heat exchanger and burners. In a utility room installation, the
door shall be wide enough to allow the boiler to enter or to permit
the replacement of another appliance.
WHEN SUCH LOCATIONS CANNOT BE AVOIDED, A SUITABLE
DRAIN PAN SHOULD BE INSTALLED UNDER THE BOILER. Such
pans should be fabricated with sides at least 2-1/2" (6.5 cm) deep,
with length and width at least 2" (5.1 cm) greater than the dimensions
of the boiler and must be piped to an adequate drain. The pan
must not restrict combustion air flow.
Two inch (5.1 cm) clearance is allowable from combustible
construction to hot water pipes. Sufficient clearance should be
provided at one end of the boiler to permit access to heat exchanger
tubes for cleaning.
WARNING
THERE IS A RISK IN USING FUEL BURNING APPLIANCES IN
ROOMS OR AREAS WHERE GASOLINE, OTHER FLAMMABLE
LIQUIDS OR ENGINE DRIVEN EQUIPMENT OR VEHICLES ARE
STORED, OPERATED OR REPAIRED. FLAMMABLE VAPORS ARE
HEAVY AND TRAVEL ALONG THE FLOOR AND MAY BE IGNITED
BY THE IGNITER OR MAIN BURNER FLAMES CAUSING FIRE OR
EXPLOSION. SOME LOCAL CODES PERMIT OPERATION OF GAS
APPLIANCES IF INSTALLED 18 INCHES (46.0 CM) OR MORE
ABOVE THE FLOOR. THIS MAY REDUCE THE RISK IF LOCATION
IN SUCH AN AREA CANNOT BE AVOIDED.
Access to control box items such as the Central Control Board,
Ignition Control Boards and wiring harnesses is provided through
a panel on the left side of the unit. An 18" (46.0 cm) minimum
clearance is recommended.
These boilers are approved for installation on noncombustible
flooring in an alcove with minimum clearance to combustibles of:
3 inches (7.6 cm) Right Side, and Back; 6 inches (15.2 cm) Top,
Front Alcove, 12 inches (30.5 cm) Left Side and 6 inches (15.2 cm)
Vent.
FLAMMABLE ITEMS, PRESSURIZED CONTAINERS OR ANY
OTHER POTENTIAL FIRE HAZARDOUS ARTICLES MUST NEVER
BE PLACED ON OR ADJACENT TO THE BOILER.
For installation on combustible flooring use the Combustible Floor
Kit. The combustible floor kit base adds 4" (10.1 cm) to the overall
height of the boiler. See figure 3.
OPEN CONTAINERS OF FLAMMABLE MATERIAL SHOULD NOT
BE STORED OR USED IN THE SAME ROOM WITH THE BOILER.
If the boiler is installed above the level of heating system terminal
units, a low water cutoff device must be installed in the boiler outlet
at the time of installation.
For installation locations with elevations above 4,500 feet
(1350 m), consult the factory.
WARNING
UNDER NO CIRCUMSTANCES SHOULD THE EQUIPMENT ROOM
WHERE THE BOILER IS INSTALLED EVER BE UNDER NEGATIVE
PRESSURE. PARTICULAR CARE MUST BE TAKEN WHEN
EXHAUST FANS, COMPRESSORS, AIR HANDLING EQUIPMENT,
ETC., MAY INTERFERE WITH THE COMBUSTION AND
VENTILATION AIR SUPPLIES OF THIS BOILER.
MODEL
CHEMICAL VAPOR CORROSION
Heat exchanger corrosion and component failure can be caused
by the heating and breakdown of airborne chemical vapors. Spray
can propellants, cleaning solvents, refrigerator and air conditioning
refrigerants, swimming pool chemicals, calcium and sodium
chloride, waxes, and process chemicals are typical compounds
which are corrosive. These materials are corrosive at very low
concentration levels with little or no odor to reveal their presence.
COMBUSTIBLE FLOOR KIT NO.
(GB/GW)-1000
211093
(GB/GW)-1300
211093-1
(GB/GW)-1500
211093-2
(GB/GW)-1850
211093-3
(GB/GW)-2100
211093-4
(GB/GW)-2500
211093-5
Figure 3: Boiler on Combustible Floor Base and Kit Numbers
LEVELLING
Each unit must be checked after installation to be certain that it is
level.
Products of this sort should not be stored near the boiler. Also, air
which is brought in contact with the boiler should not contain any of
these chemicals. If necessary, uncontaminated air should be
obtained from remote or outside sources. Failure to observe this
requirement will void the warranty.
AIR REQUIREMENTS
WARNING
FOR SAFE OPERATION, AN AMPLE SUPPLY OF AIR MUST BE
7
PROVIDED FOR PROPER COMBUSTION AND VENTILATION IN
ACCORDANCE WITH THE NATIONAL FUEL GAS CODE, ANSI
Z223.1 OR CAN/CSA-B149.1 AND .2 (LATEST EDITIONS) OR
APPLICABLE PROVISIONS OF THE LOCAL BUILDING CODES.
AN INSUFFICIENT SUPPLY OF AIR MAY RESULT IN A YELLOW,
LUMINOUS BURNER FLAME, CARBONING OR SOOTING OF THE
FINNED HEAT EXCHANGER, OR CREATE A RISK OF
ASPHYXIATION. DO NOT OBSTRUCT THE FLOW OF
COMBUSTION AND VENTILATION AIR.
sufficient openings for air must be provided in the walls.
UNDERSIZED OPENINGS WILL CAUSE AIR TO BE DRAWN INTO
THE ROOM THROUGH THE CHIMNEY, CAUSING POOR
COMBUSTION. SOOTING MAY RESULT WITH AN INCREASED
RISK OF ASPHYXIATION.
VENTING
!
This boiler is approved to be vented as a Category I, Category III
(horizontal venting), or a Direct Vent appliance. The Horizontal and
Direct Venting options require a special vent kit.
UNCONFINED SPACE
In buildings of conventional frame, brick or stone construction,
unconfined spaces may provide adequate air for combustion.
TABLE 6: DIRECT VENT KITS
Horiz. or Horiz. Direct Vent Kit No.
211090
211090-1
211090-1
211090-4
211090-2
211090-3
Vertical Direct Vent Kit No.
211089
211089-1
211089-1
211089-4
211089-2
211089-3
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, 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
(a) U. S. INSTALLATIONS
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
WITHIN 12 INCHES OF THE ENCLOSURE TOP AND ONE WITHIN
12 INCHES OF THE ENCLOSURE BOTTOM. Each opening shall
have a free area of at least one square inch per 1000 Btuh of the
total input of all appliances in the enclosure, but not less than 100
square inches.
Model Number
G(W,B) 1000
G(W,B) 1300
G(W,B) 1500
G(W,B) 1850
G(W,B) 2100
G(W,B) 2500
Model Number
G(W,B) 1000
G(W,B) 1300
G(W,B) 1500
G(W,B) 1850
G(W,B) 2100
G(W,B) 2500
CAUTION
WHEN VENTING THE GENESIS BOILER THROUGH AN
OVERSIZED CHIMNEY (INCLUDING MASONRY CHIMNEYS),
ADDITIONAL CARE MUST BE EXERCISED TO ASSURE PROPER
DRAFT. FOR PROPER OPERATION, A MINIMUM DRAFT OF -0.02"
W.C. AND A MAXIMUM DRAFT OF -0.04" W.C. MUST BE MAINTAINED.
IN INSTANCES OF EXCESSIVE DRAFT, A BAROMETRIC DAMPER
MAY BE REQUIRED TO ASSIST IN MAINTAINING THE PROPER
DRAFT. DRAFT SHOULD BE MEASURED 2 FEET (0.6 M) ABOVE
THE BOILER VENT COLLAR.
If the confined space is within a building of tight construction, air for
combustion, ventilation, and draft hood dilution must be obtained
from outdoors. When directly communicating with the outdoors or
communicating with the outdoors through vertical ducts, two
permanent openings, located in the above manner, shall be
provided. Each opening shall have a free area of not less than one
square inch per 4000 Btuh 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 Btuh of the total
input of all appliances in the enclosure.
WARNING
THE INSTRUCTIONS IN THIS SECTION ON VENTING THE BOILER
MUST BE FOLLOWED TO AVOID CHOKED COMBUSTION OR
RECIRCULATION OF FLUE GASES. SUCH CONDITIONS CAUSE
SOOTING OR RISKS OF FIRE AND ASPHYXIATION.
(b) CANADIAN INSTALLATIONS
Ventilation of the space occupied by the boiler(s) shall be provided
by an opening for ventilation air at the highest practical point
communicating with outdoors. The total cross- sectional area shall
be at least 10% of the area of the combustion air opening but in no
case shall the cross-sectional area be less than 10 square inches
(6500 mm2).
CONNECTING BOILER TO A COMMON VENT
Do not connect the boiler to a common vent or chimney with solid
fuel burning equipment. This practice is prohibited by most local
building codes as is the practice of venting gas fired equipment to
the duct work of ventilation systems.
Where a separate vent connection is not available and the vent
pipe from the boiler must be connected to a common vent with an
oil burning furnace, the vent pipe should enter the common vent or
chimney at a point ABOVE the flue pipe from the oil furnace.
In addition to the above, there shall be permanent air supply
opening(s) having a cross-sectional area of not less than 1 square
inch per 7,000 BTUH (310 mm2/KW) up to and including 1,000,000
BTUH plus 1 square inch per 14,000 BTU in excess of 1,000,000
BTUH. This opening(s) shall be located at, or ducted to, a point
neither more than 18" (46.0 cm) nor less than 6 inches (15.2 cm)
above the floor level.
UL/ULC listed double wall type B-1 gas vents, through 16" diameter,
can be installed in heated and unheated areas and can pass
through floors, ceilings, partitions, walls and roofs, provided the
required clearance is observed.
Where power vented equipment is used in the same room as the
boiler, sufficient air openings must be supplied. UNDERSIZED
OPENINGS MAY RESULT IN INSUFFICIENT AIR FOR
COMBUSTION.
At the time of removal of an existing boiler, the following steps shall
be followed with each appliance remaining connected to the
common venting system. Perform these steps while the other
appliances remaining connected to the common venting system
are not in operation.
Where an exhaust fan is installed in the same room with a boiler,
8
LOCATION REQUIREMENTS (INTAKE/EXHAUST)
1. Seal any unused opening in the common venting system.
2. Visually inspect the venting system for proper size and horizontal
pitch and determine there is no blockage or restriction, leakage,
corrosion or other unsafe condition.
3. Isolate the space containing the appliance(s) remaining
connected to the common venting system as much as possible
by closing all openings (windows, doors, etc.) connected to
other spaces in the building. Turn on any exhaust fans to their
maximum setting and close fireplace dampers. Note: DO NOT
operate summer exhaust fan.
4. Test fire the appliance(s) being inspected, making sure to follow
the manufacturers lighting and operating instructions.
Appliance(s) operating controls should be adjusted to provide
continuous service.
5. Check vent pressure of appliance 24 inches (61.0 cm) above
boiler vent collar. Vent pressure should be maintained between
-0.02" W. C. and -0.04" W.C. to assure proper operation. For
appliances with a draft hood, check for spillage with mirror,
smoke or other device five minutes after placing appliance in
operation.
6. After it has been determined that each appliance remaining
connected to the common venting system properly vents when
tested as outlined above, return doors, windows, exhaust fans,
fireplace dampers and other gas burning appliances to their
previous conditions of use.
Intake/Exhaust Installation Requirements (See figure 4):
1. The termination must be 12 inches (30.5 cm) above snow or
grade level whichever is higher.
2. Due to normal formation of water vapor in the combustion
process, horizontal terminations must not be located over areas
of pedestrian or vehicular traffic, i.e. public walkways or over
areas where condensate could create a nuisance or hazard.
This is especially true in colder climates where ice buildup is
likely to occur. A.O. Smith Corporation will not be held liable for
any personal injury or property damage due to any dislodging
of ice.
3. The minimum distance for any window, gravity air inlet to a
building, or from gas or electric meter(s) is 6 feet (1.8 m)
horizontally, 4 feet (1.2 m) below and 24 inches (61.0 cm) above.
4. The minimum distance from inside corner formed by two
exterior walls is 6 feet (1.8 m) but 10 feet (3.1 m) is
recommended where possible.
5. Maintain a minimum distance of 4 feet (1.2 m) from any soffit or eve
vent to the exhaust terminal.
6. Maintain a minimum distance of 10 feet (3.1 m) from any forced
air inlet to a building. Any fresh air or make up air inlet such as
a dryer or furnace area is considered to be a forced air inlet.
7. Avoid areas where condensate drainage may cause problems
such as above planters, patios, or adjacent to windows where
the steam from the flue gases may cause fogging.
8. Select the point of wall penetration where the minimum 1/4" per
foot (2 cm/m) of slope up can be maintained.
9. The through the wall termination kit is suitable for zero clearance
to combustible materials.
10.The mid point of the termination elbow must be a minimum of
12 inches (30.5 cm) from the exterior wall.
All boiler venting systems shall be installed in accordance with the
National Fuel Gas Code, ANSI Z223.1 or CAN/CSA-B149.1 and .2
(and latest addendums), or applicable provisions of the local
building codes.
CAUTION
Direct venting into dead air spaces such as alleys, atriums and
inside corners can cause recirculation of flue gases.
Recirculation of flue gases will cause sooting, premature failure
of the heat exchanger and icing of the combustion air intake
during severe cold weather. To prevent the recirculation of flue
gases, maintain as much distance as possible between the
combustion air intake and the exhaust vent terminal.
Figure 4. Vent Termination Installation Clearances
9
STANDARD VENT - VERTICAL (CATEGORY I)
IMPORTANT!
VENT PRESSURE MUST BE MAINTAINED
BETWEEN -0.02" W.C. AND -0.04" W.C. AT 24"
(61.0 cm) ABOVE BOILER COLLAR.
Figure 5.
TABLE 7. STANDARD VERTICAL VENTING (CATEGORY I)
MODEL
APPLIANCE
CATEGORY
CERTIFIED
VENTING
MATERIAL
EXHAUST
VENT SIZE
(INCHES)
MAXIMUM LENGTH WITHOUT
BAROMETRIC DAMPER (FEET)
I000
I
TYPE B OR
EQUIVALENT
10”(25.4 cm)
35 Feet (10.7 m) without damper
*70 Feet (21.3 m) max. with damper
1300
1500
I
TYPE B OR
EQUIVALENT
1850
2100
I
TYPE B OR
EQUIVALENT
14"(35.6 cm)
35 Feet (10.7 m) without damper
*70 Feet (21.3 m) max. with damper
2500
I
TYPE B OR
EQUIVALENT
16" (40.6 cm)
35 Feet (10.7 m) without damper
*70 Feet (21.3 m) max. with damper
12" (30.5 cm)
35 Feet (10.7 m) without damper
*70 Feet (21.3 m) max. with damper
* Extending venting over 70 feet (21.3 m) may require special considerations.
• Connection for the appliance exhaust vent to the stack must be as direct as possible. Maximum and minimum venting length
for Category I appliances shall be determined per the latest edition of the National Fuel Code (U.S.) and CAN/CSA-B149.1
and .2 Installation Code (Canada).
• The horizontal breaching of a vent must have an upward slope of not less than 1/4 inch per linear foot (2 cm/m) from the boiler
to the vent terminal. The horizontal portion of the vent shall be supported to maintain clearances and to prevent physical damage
or separation of joints.
10
STANDARD VENT - HORIZONTAL (CATEGORY III)
Figure 6.
TABLE 8. STANDARD HORIZONTAL VENTING (CATEGORY III)
MODEL
APPLIANCE
CATEGORY
CERTIFIED
VENTING
MATERIAL
EXHAUST
VENT SIZE
(INCHES)
MAXIMUM
VENT LENGTH
(FEET)
I000
III
STAINLESS
STEEL
10”(25.4 cm)
70' (21.3 m)
1300
1500
III
STAINLESS
STEEL
12" (30.5 cm)
70' (21.3 m)
1850
2100
III
STAINLESS
STEEL
14"(35.6 cm)
70' (21.3 m)
2500
III
STAINLESS
STEEL
16" (40.6 cm)
70' (21.3 m)
WARNING: No substitutions of flue pipe or vent cap material are allowed. Such substitutions would jeopardize the
safety and health of inhabitants.
• A maximum of two elbows can be used on inlet and outlet vent piping respectively. Each elbow is equal to 10 feet (3 m) of
straight pipe.
• Use only special gas vent pipes listed for use with Category III gas burning heaters, such as stainless steel Saf-T-Vent
by Heat Fab, Inc., available from A.O. Smith WPC, 5621 W. 115th Street, Alsip, IL 60803 Phone: 1-800-433-2545 or
Fax: 1-800-433-2515. Pipe joints must be positively sealed.
11
DIRECT VENT - VERTICAL (CATEGORY I)
Figure 7.
TABLE 9. DIRECT VENT (VERTICAL EXHAUST CONFIGURATIONS)
MODEL
APPLIANCE
CERTIFIED
EXHAUST VENT
MAXIMUM
CATEGORY EXHAUST VENT SIZE (INCHES) EXHAUST VENT
MATERIAL
LENGTH (FEET)
AIR INTAKE
MATERIAL
AIR INLET
SIZE (INCHES)
MAXIMUM
AIR INTAKE
LENGTH (FEET)
I000
I
TYPE B OR
EQUIVALENT
10"
(25.4 cm)
35'
(10.7 m)
GAL. STEEL
PVC, ABS OR
CPVC
8"
(20.3 cm)
35'
(10.7 m)
1300
1500
I
TYPE B OR
EQUIVALENT
12"
(30.5 cm)
35'
(10.7 m)
GAL.STEEL
PVC, ABS CR
CPVC
10"
(25.4 cm)
35'
(10.7 m)
1850
I
TYPE B OR
EQUIVALENT
14"
(35.6 cm)
20'
(6.1 m)
GAL. STEEL
PVC, ABS OR
CPVC
10"
(25.4 cm)
20'
(6.1 m)
2100
I
TYPE B OR
EQUIVALENT
14"
(35.6 cm)
20'
(6.1 m)
GAL. STEEL
PVC, ABS OR
CPVC
12"
(30.5 cm)
20'
(6.1 m)
2500
I
TYPE B OR
EQUIVALENT
16"
(40.6 cm)
20'
(6.1 m)
GAL. STEEL
PVC, ABS OR
CPVC
12"
(30.5 cm)
20'
(6.1 m)
• Connection for the appliance exhaust vent to the stack must be as direct as possible. Maximum and minimum venting length
for Category I appliances shall be determined per the latest edition of the National Fuel Code (U.S.) and CAN/CSA-B149.1
and .2 Installation Code (Canada).
• The vent should be installed so as to prevent the accumulation of condensate and, where necessary, have means provided for
drainage of condensate. The horizontal breaching of a vent must have an upward slope of not less than 1/4 inch per linear foot
(2 cm/m) from the boiler to the vent terminal. The horizontal portion of the vent shall be supported to maintain clearances and to
prevent physical damage or separation of joints.
12
DIRECT VENT - HORIZONTAL (CATEGORY III)
Figure 8.
TABLE 10. DIRECT VENT (HORIZONTAL EXHAUST CONFIGURATIONS)
MODEL
APPLIANCE
CERTIFIED
CATEGORY EXHAUST VENT
MATERIAL
I000
III
1300
1500
III
1850
III
2100
III
2500
III
VENT
SIZE
(INCHES)
MAXIMUM
VENT LENGTH
(FEET)
AIR INTAKE
MATERIAL
AIR INLET
SIZE
(INCHES)
MAXIMUM
AIR INTAKE
LENGTH (FEET)
10"
(25.4 cm)
35'
(10.7 m)
GAL. STEEL
PVC, ABS OR
CPVC
8"
(20.3 cm)
35'
(10.7 m)
(SEALED)
12"
(30.5 cm)
35'
(10.7 m)
GAL.STEEL
PVC, ABS CR
CPVC
10"
(25.4 cm)
35'
(10.7 m)
STAINLESS
(SEALED)
14"
(35.6 cm)
20'
(6.1 m)
GAL. STEEL
PVC, ABS OR
CPVC
10"
(25.4 cm)
20'
(6.1 m)
STAINLESS
(SEALED)
14"
(35.6 cm)
20'
(6.1 m)
GAL. STEEL
PVC, ABS OR
CPVC
12"
(30.5 cm)
20'
(6.1 m)
STAINLESS
(SEALED)
16"
(40.6 cm)
20'
(6.1 m)
GAL. STEEL
PVC, ABS OR
CPVC
12"
(30.5 cm)
20'
(6.1 m)
STAINLESS
(SEALED)
STAINLESS
WARNING: No substitutions of flue pipe or vent cap material are allowed. Such substitutions would jeopardize the
safety and health of inhabitants.
• A maximum of two elbows can be used on inlet and outlet vent piping respectively. Each elbow is equal to 10 feet (3 m) of
straight pipe.
• Use only special gas vent pipes listed for use with Category III gas burning heaters, such as stainless steel Saf-T-Vent by Heat
Fab, Inc. Inc., available from A.O. Smith WPC, 5621 W. 115th Street, Alsip, IL 60803 Phone: 1-800-433-2545 or
Fax: 1-800-433-2515. Pipe joints must be positively sealed.
13
STANDARD (VERTICAL) VENTING, CATEGORY I
STANDARD (HORIZONTAL) VENTING, CATEGORY III
THIS BOILER MAY BE VENTED ACCORDING TO TABLE 7 (ALSO
SEE FIGURE 5). AT LEAST TYPE B VENTING MUST BE USED
WITH THE STANDARD VENTING OPTION (thru-the-roof) USING
THE NATIONAL FUEL GAS CODE VENT TABLES.* TYPE B VENT
PIPE CANNOT BE USED IF THE BOILER IS VENTED
HORIZONTALLY OR AS A DIRECT VENT (SEE PAGES 11
THROUGH 13). ALL LOCAL UTILITY, STATE/ PROVINCIAL,
REGULATIONS ON VENTING MUST BE FOLLOWED.
Vent sizing, installation and termination shall be in accordance
with the NATIONAL FUEL GAS CODE, ANSI Z223.1 OR
CAN/CSA-B149.1 AND .2 (LATEST EDITIONS). If applicable, all
local, utility, state/provincial regulations on venting must be followed.
See table 8 for venting specifications. The exhaust vent pipe must
be of a type listed for use with Category III gas burning heaters
such as "Saf-T-Vent" manufactured by Heat-Fab Inc.
VENT SIZING, INSTALLATION AND TERMINATION SHALL BE IN
ACCORDANCE WITH THE NATIONAL FUEL GAS CODE, ANSI
Z223.1 OR CAN/CSA-B149.1 and .2 (AND LATEST ADDENDA).*
For Category III installations, It is important that the Installed vent
be airtight. Please insure that all joints are sealed properly during
installation.
DIRECT VENT VERTICAL AND HORIZONTAL VENTING
Vent connections must be made to an adequate stack or chimney
and shall be in accordance with the National Fuel Gas Code, ANSI
Z223.1 or CAN/CSA-B149.1and .2 (and latest addenda) or
applicable provisions of the local building codes. Size and install
proper size vent pipe.
For direct vent applications this boiler may be vented according to
tables 9 and 10. For category III applications, the exhaust vent pipe
must be special gas vent pipe listed for use with category III gas
burning heaters such as "Saf-T-Vent" manufactured by Heat-Fab
Inc. This vent system must be 100% sealed with a condensate
trap located as close to the boiler as possible.
Horizontal runs of vent pipe shall be securely supported by
adequately placed (approximately every 4 feet [1.2 m]),
noncombustible hangers suitable for the weight and design of the
materials employed to prevent sagging and to maintain a minimum
upward slope of 1/4" per foot (2 cm/m) from the boiler to the vent
terminals. Dampers or other obstructions must not be installed in
the vent. Be sure that the vent connector does not extend beyond
the inside wall of the chimney.
When sizing exhaust piping and intake air piping, 90-degree elbows
are equivalent to 10 feet (3.1 m) of straight pipe and 45-degree
elbows are equal to 5 feet (1.5 m) of straight pipe.
The intake air piping can be PVC, CPVC, ABS or any suitable intake
air piping that can be sealed.
Combustion air from outside the building ducted to boiler air inlet
(Ducted Air Application) cannot be used in rooms with negative
pressure.
Table 11: VENT CONNECTION
VENT CONNECTOR
MODEL NUMBER
G(W,B) 1000
10" (25.4 cm)
G(W,B) 1300
12" (30.5 cm)
G(W,B) 1500
12" (30.5 cm)
G(W,B) 1850
14" (35.6 cm)
G(W,B) 2100
14" (35.6 cm)
G(W,B) 2500
16" (40.6 cm)
For vent arrangements other than table 7 and for proper boiler
operation, a barometric damper is required to maintain draft
between -0.02" W.C.. and -0.04" W.C. at 2 feet (0.6 m) above the
boiler vent collar.
HORIZONTAL VENT INSTALLATION
This boiler can be vented through the rear of the cabinet with the
use of the Fluebox and vent adaptor. Any of the previous venting
configurations can be installed with rear connections.
To change the unit to rear exhaust:
1. The vent collar and cover plates must be removed from the top
and rear of the unit.
2. Trim the insulation from around the rear flue hole in the jacket
and the fluebox. Support insulation from inside the fluebox to
facilitate cutting. Use safety precautions such as gloves. Place
the gasket and vent adaptor in the horizontal position. Place the
gasket and flue plate in the vertical position as shown in
figure 9.
Figure 9. Switching from Vertical to Horizontal Venting
14
SYSTEM INSTALLATION
CONVENTIONAL SPACE HEATING INSTALLATION
GENERAL
Modern fin type boilers are exceptionally fast heating units. The low
water volumes in relation to firing rates require special attention to
water flow rates for smooth, efficient operation. These
considerations for the A. O. Smith copper heat exchanger boilers
are covered below.
If the system is to be filled with water for testing or other purposes
during cold weather and before actual operation, care must be
taken to prevent a down draft entering the boiler or freezing air from
contacting the system. Failure to do so may cause the water in the
system to freeze with resulting damage to the system. Damage
due to freezing is not covered by the warranty.
Refer to table 4 showing flow rate vs. pressure drop and temperature
rise.
Good practice requires that all piping, etc., be properly supported.
Figure 10 shows a typical installation of the boiler.
The boilers described in this manual may be used for space
(hydronic) heating or for the heating of potable water. If the heater
is to be used for hydronic space heating, follow the instructions on
pages 15-17 given for equipment required for installation as in
Figure 10. However, if units are to be used for heating potable
water, the information describing specific systems is found on
pages 17-19. See figures 11 and 13. Installations must comply
with all local codes.
A system with several flow controlled zones, or with a 3-way mixing
valve system could present a flow rate to the boiler of less than
required for a maximum of 50°F (28°C) temperature rise. Design
system with compensating bypasses to the boiler.
HYDRONIC INSTALLATION
This bypass may also be used with multiple boilers manifolded for
reverse-return flow. The system bypass would be installed from
boiler outlet to suction side of pump.
A system bypass should be installed as shown in figure 10 to
prevent boiler circulation starvation when the system zones call for
reduced flow.
The following is a brief description of the equipment required for
installations noted in this manual. All installations must comply
with local codes (see figure 10).
The boiler piping system of a hot water heating boiler connected to
heating coils located in air handling units where they may be
exposed to circulating refrigerated air, must be equipped with flow
control valves or other automatic means to prevent gravity circulation
of the boiler water during the cooling cycle. It is highly recommended
that the piping be insulated.
Table 12: INSTALLATION ITEMS
NO.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
SUGGESTED ITEMS FOR INSTALLATION
PAIR OF SHORT PIPE NIPPLES, PAIR OF BOILER
LOOP TEES AND BALL VALVE BETWEEN SYSTEM
SUPPLY AND RETURN - ONE SET PER EACH BOILER
BOILER PIPE LOOP (See Sizing Data Table 4.)
BOILER CIRCULATING PUMP (See Sizing Data Table 4.)
THERMOMETER
PRESSURE GAUGE
LOW WATER CUTOFF (If Required By Local Code.)
SAFETY FLOW SWITCH (Factory-Installed)
RELIEF VALVE (Factory-Installed)
BOILER INLET - OUTLET
SYSTEM SUPPLY TEMPERATURE THERMOMETER
DRAIN or BLOW-DOWN VALVE
INSTALLATION AS BOILER REPLACEMENT
Installation as boiler replacement on an old system with large water
volume may result in condensation within the boiler on cold starts.
This condensing of water vapor in the combustion area can be
prevented if a portion of the system water flow is diverted past the
boiler to cause an increase in boiler temperature rise.
BYPASS BALANCING
With systems where water temperature can be expected to drop
appreciably due to long standby periods, or heavy draw down, a
bypass pipe of at least 1" size with a balancing cock should be
installed between the boiler inlet and outlet (see figure 10). When
the system first starts, the valve should be slowly opened until the
condensing ceases. This adjustment remains at a permanent
setting to establish required temperature rise across the boiler.
WATER SUPPLY LINE
These boilers can be used ONLY in a forced circulation hot water
heating system. The pump must be interlocked with the boiler to
prevent boiler operation without water circulation. See maximum
and minimum flow rate information. Since most forced circulation
systems will be of the closed type, install the water supply line as
shown on piping diagram, figure 10. Severe damage will occur if
the boiler is operated without proper water flow circulation.
AIR SEPARATOR
An air separator as shown in the piping diagram is reccommended
especially for modern commercial hydronic systems.
VENT VALVES
Fast filling of large pipe, old radiator installations (where high
pressures are not available) requires bypassing of the pressure
reducing valve. Generally, pressure purging is not possible with a
well pump system. High point air venting is essential. For details,
refer to OPERATION section of this manual on page 22.
It is recommended that automatic, loose key or screwdriver type
vent valves be installed at each convector or radiator.
If the system is of the open type, a pressure reducing valve will not
be required as the water supply to the system will be controlled by
a manually operated valve. An overhead surge tank is required. A
MINIMUM PRESSURE OF 15 PSI (100 kPa) MUST BE MAINTAINED
ON THE BOILER AT ALL TIMES to avoid potential damage to the
boiler that may not be covered by the warranty.
Split systems with individual supply and return lines from the boiler
room should normally have this piping connected to supply and
return manifold headers near the boiler. To achieve good water
distribution with minimum pressure drop for several circuits,
manifolds should be larger than system loops.
SYSTEM HEADERS
15
The circuits should be spaced on the header at a minimum of
3" (7.6 cm) center to center. Install a balancing cock in each return
line.
installation might be controlled directly from space temperature
thermostat(s). Multiple boiler installations are more effective when
the boilers are sequenced in and out of operation by some form of
main water temperature controller. With one or two boilers, individual
control settings at progressive temperature may be used. For more
than two boilers, electronic sequencing controlling is
recommended.
Manifold headers are recommended for split systems with or
without zone valves and also those installations with zone
circulators. If the system is to be split at remote points, good practice
requires special attention be given to main pipe sizing to allow
balancing of water flow.
Individual controls, or the separate stages of a step controller,
should fire a boiler and also start the boiler loop circulator whenever
that boiler is fired. Some large installations may require the firing
of more than one boiler per stage.
COOLING PIPING
When the boiler is used in conjunction with a refrigeration system
it must be installed so that the chilled medium is piped in parallel
with the boiler. Appropriate valves, manual or motorized, must be
provided to prevent the chilled medium from entering the boiler.
The system or primary circulator may or may not be controlled by
the boiler sequencer. When this pump is operated through the first
switch of any type of step controller, care should be taken to
determine if a motor starter is needed due to insufficient switch
capacity.
Water temperature in the heating system must be reduced to less
than 100°F before cooling system is started, or damage to the
chiller unit may occur.
If the primary pump is controlled by a manual switch or any other
controllers, the electric current supply to the boiler group should be
through the primary pump controller. The fast response of
A.O. Smith boilers eliminates any need to maintain boiler
temperature when the system is satisfied. Wiring should always
prevent firing of boiler(s) when there is no water flow in the
mains.
If the boiler is connected to chilled water piping or heating coils
exposed to refrigerated air, the boiler piping system must be
equipped with flow control valves or other automatic means to
prevent gravity circulation through the boiler during the cooling cycle.
Primary/secondary pumping of both the chiller(s) and the boiler(s)
is an excellent winter-summer change-over method, because
cooling flow rates are much more than heating flow rates. In this
way each system (heating or cooling) is circulated independently.
SPACE HEATING APPLICATIONS
Installation diagrams show safety flow switches in the outlet piping
from each boiler as good protection against any boiler being fired
when the boiler loop circulator is not in operation. These safety flow
switches will also provide some protection if there is a loss of water.
Controlling of these systems is decided mainly by the type of
building system controlling that is desired. A single boiler
Multiple boiler installations are especially adapted to the use of
outdoor reset for main water temperatures. This feature is not
Figure 10. Single or Multiple Boiler Installation Diagram
16
mandatory but offers smooth, efficient operation of a modern
system.
HARD WATER CONDITIONS
Where hard water conditions exist, water softening or the threshold
type of water treatment is recommended. This will protect the
dishwashers, coffee urns, water heaters, water piping and other
equipment. When water softening or water treatment is not practical,
a comparatively easy method of periodic lime removal from the unit
must be employed.
Normal use of flow control valves is required to prevent cross
circulation of zones as with any multiple pump system.
Large systems with multiple boilers should include main water
temperature controls (with or without outdoor reset) to sequence
the boiler on and off, in relation to the load on the system.
WARNING
24 VAC System Controller (Optional)
GB models require a field supplied 24VAC operating control to be
installed in the system such as: loop thermostat, indoor/outdoor
reset control, sequencing panel, or energy management system.
The connection for such devices is located in the 24 VAC junction
box at the rear of the unit. A 24 VAC thermostat/aquastat can only be
used as an "On/Off" switch for the unit. The actual controlling of the
staging will be through either the inlet or tank probe. To use a 24 VAC
system controller, dip switch "E" on the CCB must be switched to the
"on" position. See figure 14.
LIME ACCUMULATION CAN REDUCE THE LIFE OF THE
EQUIPMENT, REDUCE EFFICIENCY AND WASTE FUEL. BOILER
FAILURE DUE TO LIME OR SCALE BUILDUP VOIDS THE
WARRANTY.
Tank Probe (Optional)
In addition to the Inlet and Outlet/ECO Probes, units can be
optionally equipped with a tank Probe. The connection for the tank
probe is located in the 24VAC junction box at the rear of the unit.
The tank Probe can be configured to control the staging of the unit.
See Tank Probe Installation section below for additional
information.
INTERNAL CONTAMINANTS
The system must be internally cleaned and flushed after a new or
replacement unit has been installed to remove contaminants that
may have accumulated during installation. This is doubly important
when a replacement unit is installed into an existing system where
Stop Leak or other boiler additives have been used.
TANK PROBE INSTALLATION PROCEDURE
A tank probe is supplied with each hot water supply boiler (GW). To
connect the tank probe to the boiler, remove the cover from the 24
VAC junction box at the rear of the unit. Connect the probe wires
across terminals 1 & 2. (The wires leading to the terminals will be
yellow.) Check the field connection diagram located on this cover
of the junction box to assure proper wiring.
All systems should be completely flushed with a grease removing
solution to assure trouble-free operation. Pipe joint compounds,
soldering paste, grease on tubing and pipe all tend to contaminate
a system.
Once the tank probe has been connected to the boiler, it must be
designated as the controlling probe for the system. This is
accomplished by changing two Dip Switch settings on the Central
Control Board. First, Dip Switch "D" must be set to the "ON" position
to designate the tank probe as the controlling probe. Second, Dip
Switch "G" must be set to the "OFF" position to limit the maximum
tank probe temperature for GW applications. It is also advisable to
make sure Dip Switch "F" is set to the "OFF" position which sets the
Outlet temperature Set-Point to 210°F (99°C). See figure 14. Failure
to do this will void the warranty. If the tank probe is not designated
as the controlling probe, the staging of the unit will be controlled by
the Inlet Probe and will not use the desired tank temperature as its
base. Once the tank Probe is designated as the controlling probe,
the Inlet Water Temperature on the display will default to the tank
temperature.
Failure to clean and flush the system can cause solids to form on
the inside of the heat exchanger, can produce acid concentrations
that become corrosive, can allow excessive amounts of air or other
gases to form which could block circulation, foul system
accessories and damage circulator seals and impellers.
It is recommended that after installation, the boiler and system
when filled should include the proper percentage of cleaning
solution related to approximate water volume of the system. Fire
and circulate for about one hour and then flush clean with fresh
water. Commercial grease removing solutions are available.
Before operating the boiler, the entire system must be filled with
water, purged of air and checked for leaks. Do not use Stop Leak or
other boiler compounds. The gas piping must also be leak tested.
THE WATER HEATER SHOULD BE LOCATED IN AN AREA WHERE
THE GENERAL PUBLIC DOES NOT HAVE ACCESS TO SET
TEMPERATURES.
Refer to "Connection Diagram" (figure 20) and figure 12 in order to
connect the tank probe to the boiler.
See section titled "PROCEDURES FOR SETTING TANK PROBE
TEMPERATURE", following the Lighting Instructions for instructions
on how to set the temperature.
HOT WATER SUPPLY BOILER
INSTALLATION
EXPANSION TANK
WATER LINE CONNECTIONS
If the system is of the closed type, install an expansion tank as
shown in figures 11 and 13. The sizing of the expansion tank for a
closed system is very important and is directly related to the total
water volume of the system. Refer to ASME or other reliable
specifications for sizing.
Where excessive heat exchanger condensation exists due to
continued low inlet water temperatures (below 120oF), a bypass
balance loop must be installed (see figures 11 and 13).
17
ONE GENESIS (MODEL GW) HOT WATER SUPPLY BOILER WITH HORIZONTAL TANK
PRESSURE RELIEF VALVE RATING SHOULD
NOT EXCEED PRESSURE CAPACITY OF ANY
COMPONENT IN THE SYSTEM.
INSTALL THERMAL EXPANSION
TANK ON COLD WATER
SUPPLY LINE, IF CHECK VALVE
OR PRESSURE REDUCING
VALVE IS USED IN SUPPLY.
PIPING SHOULD CONFORM TO LOCAL CODES.
BALL VALVES ARE SHOWN FOR SERVICING
BOILER. HOWEVER, LOCAL CODES SHALL
GOVERN THEIR USAGE.
DANGER
TEMPERATURE SETTING SHOULD NOT EXCEED
SAFE USE TEMPERATURE AT FIXTURES.
SEE WATER TEMPERATURE CONTROL
WARNING ON PAGE 23. IF HIGHER PREHEAT
TEMPERATURES ARE NECESSARY TO OBTAIN
ADEQUATE BOOSTER OUTPUT, ADD AN
ANTI-SCALD VALVE FOR HOT WATER
SUPPLIED TO FIXTURES.
WARNING
THE WATER MANIFOLD IS NOT DESIGNED TO
SUPPORT THE WEIGHT OF THE WATER PIPING
SYSTEM. AS ON ALL BOILER INSTALLATIONS,
SPECIAL CARE MUST BE TAKEN TO ENSURE
PROPER SUPPORT.
TWO TEMPERATURE WATER
MIXING VALVE APPLICATION
CIRCULATING RETURN
LINE CONNECTIONS
• TEMPERED WATER LOOP, IF USED,
CONNECT TO POINT R.
• STORED TEMPERATURE WATER LOOP,
IF USED, CONNECT TO ANY OPENING
NEAR BOTTOM OF TANK.
MODELS
MODELS
MINIMUM
PIPE SIZE
INCHES
GW-1000
THRU
2500
2 1/2"
NPT
FACTORY PUMP SIZING
BASED ON 50 EQUIVALENT
FEET (15.2 m) OF PIPE.
Figure 11. Single boiler with horizontal tank.
Encase field-supplied wires
between tank probe and junction
box with 1/2" field supplied
conduit. "Pigtails" of fieldsupplied wires should be spliced
to "pigtails" of tank probe and
connected to 24 VAC junction box
(see figure 20). This conduit and
wiring should be separate from
any other conduit/wiring to guard
against EMI (electromagnetic
interference).
Figure 12. Tank probe installation.
18
IMPORTANT
SAFETY FLOW SWITCH PROTECTS THE
BOILER IN CASE OF WATER SERVICE
INTERRUPTION OR CIRCULATOR FAILURE.
•
X


PIPE TO OPEN DRAIN
FACTORY-INSTALLED ON UNIT
SUPPLIED WITH UNIT
FIELD-INSTALLED
ONE GENESIS (MODEL GW) HOT WATER SUPPLY BOILER WITH VERTICAL TANK
PRESSURE RELIEF VALVE RATING SHOULD NOT EXCEED PRESSURE CAPACITY OF ANY COMPONENT IN THE SYSTEM.
PIPING SHOULD CONFORM TO LOCAL CODES.
BALL VALVES ARE SHOWN FOR SERVICING BOILER. HOWEVER, LOCAL CODES SHALL GOVERN THEIR USAGE.
IMPORTANT
SAFETY FLOW SWITCH PROTECTS THE BOILER IN CASE OF WATER SERVICE INTERRUPTION OR CIRCULATOR FAILURE.
•
X


PIPE TO OPEN DRAIN
FACTORY INSTALLED ON UNIT
SUPPLIED WITH UNIT
FIELD-INSTALLED
DANGER
TEMPERATURE SETTING SHOULD NOT EXCEED SAFE USE
TEMPERATURE AT FIXTURES. SEE WATER TEMPERATURE
CONTROL WARNING ON PAGE 23. IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE
BOOSTER OUTPUT, ADD AN ANTI-SCALD VALVE FOR HOT
WATER SUPPLIED TO FIXTURES.
TWO TEMPERATURE WATER
MIXING VALVE APPLICATION
MODELS
MODELS
GW-1000
THRU
2500
INSTALL THERMAL EXPANSION
TANK ON COLD WATER SUPPLY
LINE, IF CHECK VALVE OR
PRESSURE REDUCING VALVE
IS USED IN SUPPLY.
MINIMUM
PIPE SIZE
INCHES
2 1/2"
NPT
FACTORY PUMP SIZING BASED
ON 50 EQUIVALENT FEET
(15.2 m) OF PIPE.
CIRCULATING RETURN
LINE CONNECTIONS
• TEMPERED WATER LOOP, IF USED,
CONNECT TO POINT R.
• STORED TEMPERATURE WATER LOOP,
IF USED, CONNECT TO ANY OPENING
NEAR BOTTOM OF TANK.
Figure 13. Single boiler with vertical tank.
19
20 Ft.
(6.10)
30 Ft.
(9.14)
----990,000
290
1,900,000
556
3,000,000
879
5,300,000
1,552
10,900,000
3,192
40 Ft.
(12.19)
--------1,680,000
492
2,650,000
776
4,750,000
1,391
9,700,000
2,841
50 Ft.
(15.24)
--------1,520,000
445
2,400,000
703
4,300,000
1,259
8,800,000
2,577
60 Ft.
(18.29)
--------1,400,000
410
2,250,000
659
3,900,000
1,142
8,100,000
2,372
70 Ft.
(21.34)
--------1,300,000
381
2,050,000
600
3,700,000
1,084
7,500,000
2,197
80 Ft.
(24.38)
--------1,220,000
357
1,950,000
571
3,450,000
1,010
7,200,000
2,109
90 Ft.
(27.43)
--------1,150,000
337
1,850,000
542
3,250,000
952
6,700,000
1,962
100 Ft.
(30.48)
--------1,020,000
299
1,650,000
483
2,950,000
864
6,000,000
1,757
125 Ft.
(38.10)
------------1,500,000
439
2,650,000
776
5,500,000
1,611
150 Ft.
(45.72)
------------1,370,000
401
2,450,000
718
5,000,000
1,464
175 Ft.
(53.34)
------------1,280,000
375
2,280,000
668
4,600,000
1,347
200 Ft.
(60.96)
40 Ft.
(12.19)
70 Ft.
(21.34)
80 Ft.
(24.38)
90 Ft.
(27.43)
100 Ft.
(30.48)
125 Ft.
(38.10)
150 Ft.
(45.72)
175 Ft.
(53.34)
----------------------------------------------------------------1,263,600 1,170,000 1,076,400 1,014,000
--------370
343
315
297
--------2,371,200 2,184,000 2,028,000 1,903,200 1,794,000 1,591,200 1,482,000 1,326,000
694
640
594
557
525
466
434
388
3,744,000 3,510,000 3,198,000 3,042,000 2,886,000 2,574,000 2,340,000 2,137,200
1,097
1,028
937
891
845
754
685
626
6,708,000 6,084,000 5,772,000 5,382,000 5,070,000 4,602,000 4,134,000 3,822,000
1,965
1,782
1,690
1,576
1,485
1,348
1,211
1,119
13,728,000 12,636,000 11,700,000 11,232,000 10,452,000 9,360,000 8,580,000 7,800,000
4,021
3,701
3,427
3,290
3,061
2,741
2,513
2,284
60 Ft.
(18.29)
Length of Pipe in Feet (Metres)
50 Ft.
(15.24)
--------1,404,000
411
2,620,800
768
4,134,000
1,211
7,410,000
2,170
15,132,000
4,432
------------1,248,000
366
1,999,800
585
3,556,800
1,042
7,176,000
2,102
200 Ft.
(60.96)
----1,180,000
346
2,200,000
644
3,520,000
1,031
6,250,000
1,830
12,800,000
3,749
Length of Pipe in Feet (Metres)
Maximum Capacity of Pipe in BTU/hr and kW for Gas Pressures of 14 in. W.C. (0.5 psi) or Less and a Pressure Drop of 0.5 in. W.C.
(based on 0.60 Specific Gravity Gas w/Heating Value of 1,000 BTU’s/Ft3)
Table 13. Suggested Pipe Size For Multiple Gas Appliances (Natural)
10 Ft.
(3.05)
BTU/hr 1,400,000
--kW
410
--BTU/hr 2,100,000 1,460,000
kW
615
428
BTU/hr 3,950,000 2,750,000
kW
1,157
805
BTU/hr 6,300,000 4,350,000
kW
1,845
1,274
BTU/hr 11,000,000 7,700,000
kW
3,222
2,255
BTU/hr 23,000,000 15,800,000
kW
6,736
4,627
Nominal
Iron Pipe
Size
Cap.
(Inches)
1 1/4"
1 1/2"
2"
2 1/2"
3"
4"
30 Ft.
(9.14)
------------1,482,000 1,201,200 1,029,600
434
352
302
2,277,600 1,840,800 1,544,400
667
539
452
4,290,000 3,432,000 2,964,000
1,256
1,005
868
6,786,000 5,491,200 4,680,000
1,987
1,608
1,371
12,012,000 9,750,000 8,268,000
3,518
2,856
2,421
24,648,000 19,968,000 17,004,000
7,219
5,848
4,980
20 Ft.
(6.10)
Maximum Capacity of Pipe in BTU/hr and kW for Gas Pressures of 14 in. W.C. (0.5 psi) or Less and a Pressure Drop of 0.5 in. W.C.
(based on 1.53 Specific Gravity Gas w/Heating Value of 2,500 BTU’s/Ft3)
1,060,800
311
2,184,000
640
3,276,000
959
6,162,000
1,805
9,828,000
2,878
17,160,000
5,026
35,880,000
10,508
10 Ft.
(3.05)
Table 14. Suggested Pipe Size For Multiple Gas Appliances (Propane Gas)
1"
BTU/hr
kW
BTU/hr
kW
BTU/hr
kW
BTU/hr
kW
BTU/hr
kW
BTU/hr
kW
BTU/hr
kW
Nominal
Iron Pipe
Size
Cap.
(Inches)
1 1/4"
1 1/2"
2"
2 1/2"
3"
4"
20
threads of pipe joints. Do not apply compound to the first two
threads. Use compounds resistant to the action of liquefied
petroleum gases.
GAS CONNECTIONS
WARNING
THIS BOILER IS NOT INTENDED TO OPERATE AT GAS SUPPLY
PRESSURE OTHER THAN SHOWN ON THE RATING PLATE.
EXPOSURE TO HIGHER GAS SUPPLY PRESSURE MAY CAUSE
DAMAGE TO GAS VALVES WHICH CAN RESULT IN FIRE OR
EXPLOSION. IF OVERPRESSURE HAS OCCURRED SUCH AS
THROUGH IMPROPER TESTING OF GAS LINES OR EMERGENCY
MALFUNCTION OF THE SUPPLY SYSTEM, THE GAS VALVES MUST
BE CHECKED FOR SAFE OPERATION. MAKE SURE THAT THE
OUTSIDE VENTS ON THE SUPPLY REGULATORS AND THE
SAFETY VENT VALVES ARE PROTECTED AGAINST BLOCKAGE.
THESE ARE PARTS OF THE GAS SUPPLY SYSTEM, NOT THE
BOILER. VENT BLOCKAGE MAY OCCUR DURING ICE BUILD-UP
OR SNOW STORMS.
THE BOILER MUST BE ISOLATED FROM THE GAS SUPPLY PIPING
SYSTEM BY CLOSING ITS MAIN MANUAL GAS SHUT-OFF VALVE
DURING ANY PRESSURE TESTING OF THE GAS SUPPLY PIPING
SYSTEM AT TEST PRESSURES EQUAL TO OR MORE THAN 1/2
PSIG.
1. CORRECT GAS - Make sure gas on which the boiler will operate
is the same as that specified on the rating plate. Do not install
the boiler if equipped with a different type of gas. Consult your
gas supplier.
2A. SIZING GAS SUPPLY LINE (For single boiler installations).
See table 15.
WHEN LOCAL CODES REQUIRE A MAIN MANUAL SHUT-OFF
VALVE OUTSIDE THE BOILER JACKET, A SUITABLE MAIN MANUAL
SHUT-OFF VALVE MUST BE INSTALLED IN A LOCATION
COMPLYING WITH THOSE CODES.
2B. SIZING GAS SUPPLY LINE (For multiple installations of
two or more boilers). See tables 13 (Natural Gas) and 14
(Propane Gas).
TABLE 15. SINGLE UNIT INSTALLATION, SUGGESTED
PIPE SIZE
IT IS IMPORTANT TO GUARD AGAINST GAS VALVE FOULING FROM
CONTAMINANTS IN THE GAS WAYS. SUCH FOULING MAY CAUSE
IMPROPER OPERATION, FIRE OR EXPLOSION. IF COPPER
SUPPLY LINES ARE USED THEY MUST BE APPROVED FOR GAS
SERVICE.
DISTANCE FROM METER
BEFORE ATTACHING THE GAS LINE BE SURE THAT ALL GAS
PIPE IS CLEAN ON THE INSIDE.
TO TRAP ANY DIRT OR FOREIGN MATERIAL IN THE GAS SUPPLY
LINE, A DIRT LEG (SOMETIMES CALLED DRIP LEG) MUST BE
INCORPORATED IN THE PIPING. THE DIRT LEG MUST BE
READILY ACCESSIBLE AND NOT SUBJECT TO FREEZING
CONDITIONS. INSTALL IN ACCORDANCE WITH RECOMMENDATIONS OF SERVING GAS SUPPLIERS. REFER TO
NATIONAL FUEL GAS CODE, ANSI Z223.1 OR CAN/CSA -B149.1
AND .2 (AND LATEST ADDENDA).
BTU INPUT
0-50'
51-100' 101-200' 201-300' 301-500'
990,000
2"
2"
2 1/2"
2 1/2"
2 1/2"
1,300,000
2"
2 1/2"
2 1/2"
3"
3"
1,500,000
2"
2 1/2"
3"
3"
3 1/2"
1,850,000
2 1/2"
2 1/2"
3"
3"
3 1/2"
2,100,000
2 1/2"
3"
3"
3 1/2"
4"
2,500,000
2 1/2"
3"
4"
4"
4 1/2"
Use tables 13 or 14, which are taken from ANSI booklet Z223.1,
NATIONAL FUEL GAS CODE, or CAN/CSA-B149.1and .2 (and latest
addenda) to size iron pipe or equivalent gas supply line. Table 13
is based on a pressure drop of 0.5 inches of water and a specific
gravity of 0.60 approximately that of natural gas. (LP gas has an
S.G. of about 1.53). If the service pressure is five inches water
column or less, use one pipe size larger than specified in tables
13-15 in order to minimize pressure drop in the line.
Gas Pipe sizing may be larger than heater connections on
installations where a significant run of piping is required. To prevent
damage, care must be taken not to apply too much torque when
attaching gas supply pipe to gas inlet.
No additional allowance is necessary for an ordinary number of
fittings. Where it is necessary to use more than the average number
of pipe fittings i.e. elbows, tees, and valves in gas supply line, use
a pipe larger than specified to compensate for increased pressure
drop.
Fittings and unions in the gas line must be metal to metal type.
Apply joint compounds (pipe dope) sparingly and only to the male
TABLE 16. Orifice Size for Natural and Propane (LP) Gases (U.S. and Canadian Installations)
[Drill size unless otherwise indicated.]
Model
GB/GW 1000
GB/GW 1300
GB/GW 1500
GB/GW 1850
GB/GW 2100
GB/GW 2500
Rating Input
BTUH
990,000
1,300,000
1,500,000
1,850,000
2,100,000
2,490,000
Number of
Burners
10
13
15
19
21
25
Natural (Holes)
0.111" (4X)
0.111" (4X)
0.111" (4X)
0.111" (4X)
0.111" (4X)
0.111" (4X)
21
Propane (Holes)
0.071" (3X)
0.071" (3X)
0.071" (3X)
0.071" (3X)
0.071" (3X)
0.071" (3X)
WIRING CONNECTIONS
OPERATION
ALL ELECTRICAL WORK MUST BE INSTALLED IN ACCORDANCE
WITH THE MOST RECENT VERSION OF THE NATIONAL
ELECTRICAL CODE/CANADIAN ELECTRICAL CODE AND MUST
CONFORM TO LOCAL REGULATIONS.
IMPORTANT
Only qualified personnel shall perform the initial firing of the heater.
At this time the user should not hesitate to ask the start-up
technician any questions regarding the operation and maintenance
of the unit. If you still have questions, please contact the factory or
your local A.O. Smith representative.
AN ELECTRICAL GROUND IS REQUIRED TO REDUCE RISK OF
ELECTRIC SHOCK OR POSSIBLE ELECTROCUTION. Make the
ground connection to the wire provided in the electrical supply
junction box on the boiler.
Grounding and all wiring connected to this boiler must conform to
the local code authority having jurisdiction or, in the absence of
such requirements, with the National Electrical Code, ANSI/NFPA
70 or CSA-C22.2 most recent edition.
The Central Control Board and Ignition Control Boards that make
up the control system are micro-processor based which make
them vulnerable to voltage and amperage fluctuations in the power
supply. It is imperative that they be protected by a suitable
commercial-grade surge protection device.
IF ANY OF THE ORIGINAL WIRE, AS SUPPLIED WITH THE
APPLIANCE, MUST BE REPLACED, IT MUST BE REPLACED WITH
TYPE 105°C WIRE OR ITS EQUIVALENT.
The Genesis Hot Water Supply Boiler must be connected to a single
phase line source that is:
Lighting and Operating instructions are included with this manual.
By using these instructions, the user may be able to make minor
operational adjustments and save unnecessary service calls.
However the user should not attempt repairs, but should contact a
service technician or gas supplier.
GENERAL
Never operate the boiler without first making sure the boiler and
system are filled with water, in addition:
For hot water supply installations:
• Make sure a temperature and pressure relief valve is installed at
the boiler and, if used, the storage tank. Also check for leaks.
For heating boiler installations:
• Make sure that the boiler and system have been purged of air
and checked for leaks.
120 volts, 60 Hertz, and 30 Amps.
Also be sure to check the gas piping for leaks before beginning the
initial firing of the boiler.
The system controller, other than the factory-supplied tank probe
(e. g. Honeywell Aquastat) must be wired on the low voltage side of
the 24VAC rear junction box.
FILLING AND PURGING FOR HEATING
BOILER INSTALLATION
Refer to the Schematic Diagram (Figure 19) and the Connection
Diagram (Figure 20) for wire connections.
1. Fast fill system through bypass until pressure approaches
desired system pressure. Close bypass valve and permit
pressure to be established by the pressure reducing valve.
Fuse Protection
The 24 VAC circuitry is protected with a 3 amp auto fuse on the
ignition control boards and a 5 amp fuse on the Central Control
Board. If the fuse opens, a red LED located near the fuse will light
(see figures 14 and 15). If the red LED is illuminated, replace the
fuse. Repeated failure of the fuse is an indication of possible
damage to the ignition control. The 120V circuits of each ignition
control module is protected with a 10 amp fuse located inside the
control box.
2. Vent all high points in system to purge system of air.
Provisions should be made to permit manual venting of radiators
or convectors.
FILLING FOR HOT WATER SUPPLY BOILER INSTALLATION
1. Close the systems drain valve by turning handle clockwise.
2. Open a nearby hot water faucet to permit the air in the system to
Note: Four extra 3 amp fuses and one 5 amp fuse are supplied
with the boiler.
Recommended Replacement fuses:
3 Amp: Littlefuse automotive fuse PN 257003
5 Amp: Bussman Automotive fuse PN ATC5
escape.
3. Fully open the cold water inlet pipe valve allowing the heater
and piping to be filled.
4. Close the hot water faucet as water starts to flow.
5. The heater is ready to be operated.
22
2. CHECK THE INPUT. SEE SECTIONS "INLET GAS PRESSURE:"
AND SEE NATIONAL FUEL GAS CODE, ANSI Z223.1 OR CAN/
CSA - B149.1 AND .2 (AND LATEST ADDENDA) FOR
PROCEDURES.
PURGING OF GAS LINE
Gas line purging is required with new piping or systems in which
air has entered.
DANGER
CAUTION
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 A HOT WATER TAP, OR TO DRAW
THEIR OWN BATH WATER. NEVER LEAVE A CHILD OR DISABLED
PERSON UNATTENDED IN A BATHTUB OR SHOWER.
PURGING SHOULD BE PERFORMED BY PERSONS
EXPERIENCED IN THIS TYPE OF GAS SERVICE TO AVOID RISK
OF FIRE OR EXPLOSION. PURGE DISCHARGE MUST NOT
ENTER CONFINED AREAS OR SPACES WHERE IGNITION CAN
OCCUR. THE AREA MUST BE WELL VENTILATED AND ALL
SOURCES OF IGNITION MUST BE DEACTIVATED OR REMOVED.
BEFORE PLACING THE BOILER IN OPERATION, CHECK FOR
GAS LEAKAGE. USE A SOAP AND WATER SOLUTION OR OTHER
MATERIAL ACCEPTABLE FOR THE PURPOSE OF LOCATING GAS
LEAKS. DO NOT USE MATCHES, CANDLES, FLAME OR OTHER
SOURCES OF IGNITION FOR THIS PURPOSE.
THE WATER HEATER SHOULD BE LOCATED IN AN AREA WHERE
THE GENERAL PUBLIC DOES NOT HAVE ACCESS TO SET
TEMPERATURES.
WARNING
THE GAS VALVE MUST HAVE BEEN IN THE OFF POSITION FOR AT
LEAST 5 MINUTES. This waiting period is an important safety
step. Its purpose is to permit gas that may have accumulated in
the combustion chamber to clear. IF YOU DETECT GAS ODOR AT
THE END OF THIS PERIOD DO NOT PROCEED WITH LIGHTING.
RECOGNIZE THAT GAS EVEN IF IT SEEMS WEAK, MAY INDICATE
PRESENCE OF ACCUMULATED GAS SOMEPLACE IN THE AREA
WITH RISK OF FIRE OR EXPLOSION. SEE THE FRONT PAGE
FOR STEPS TO BE TAKEN.
INLET GAS PRESSURE
The inlet gas pressure is measured by removing the low gas
pressure switch located on the main gas manifold which is
upstream of the unit's combination gas valves. The maximum
value specified in the table must not be exceeded. The minimum
values shown in table 17 must be maintained under both load and
no load conditions (static and dynamic). The combination gas
valves supplied with the boiler are for low pressure service. If
upstream pressure exceeds 14.0" W.C., an intermediate gas
pressure regulator of the lockup type must be installed.
It is recommended in domestic hot water applications that lower
water temperatures be used to avoid the risk of scalding. It is
further recommended, in all cases, that the water temperature be
set for the lowest temperature which satisfies the user's hot water
needs. This will also provide the most energy efficient operation of
the boiler and minimize scale formation in the heat exchanger,
thus prolonging the life of the boiler.
TABLE 17.
Inlet Gas Pressure
Max. Inlet Pressure (Inches W.C.)
Min. Inlet Pressure (Inches W.C.)
Nat. Gas
14.0
6.0
Prop. Gas
14.0
11.0
SETTING THE WATER HEATER TEMPERATURE AT 120°F (49°C)
WILL REDUCE THE RISK OF SCALDS. Some states require
settings at specific lower temperatures. Table 18 below shows the
approximate time-to-burn relationship for normal adult skin.
MANIFOLD PRESSURE
The manifold gas pressure is measured at the pressure tap on
the downstream side of the combination gas valve(s). For natural
gas the Manifold Pressure should measure 3.5" W.C. For propane
(LP) gas, the pressure should read 10" W.C.
TABLE 18. Risk of Scalds
Temperature
Time to Produce 2nd & 3rd
Setting
Degree Burns on Adult Skin
Over 170°F (77°C)
Nearly instantaneous
160°F (71°C)
About 1/2 second
150°F (66°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) or less
More than 5 minutes
IMPORTANT
UNDER NO CIRCUMSTANCES SHALL THE GAS PRESSURE
MEASURED AT THE BURNER MANIFOLD EXCEED THAT STATED
ON THE BOILER RATING PLATE. OVERFIRING WILL RESULT IN
DAMAGE TO THE BOILER, AS WELL AS INCREASED RISK OF
FIRE, SOOTING AND ASPHYXIATION.
ADJUSTMENTS
USE ANTI-SCALD VALVE(S) in the hot water system to reduce the
risks of scalding at points of use such as lavatories, sinks and
bathing facilities.
ON INITIAL STARTUP SOME ADJUSTMENTS ARE NECESSARY.
1. CHECK MANIFOLD AND INLET GAS PRESSURES.
23
Lighting Instructions for the G(B/W) 1000 through 2500 models
FOR YOUR SAFETY READ BEFORE OPERATING
WARNING: IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY, A FIRE OR
EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR
LOSS OF LIFE.
A. THIS APPLIANCE DOES NOT HAVE A PILOT. IT IS
EQUIPPED WITH AN IGNITION DEVICE WHICH
AUTOMATICALLY LIGHTS THE BURNER. DO NOT TRY TO
LIGHT THE BURNER BY HAND.
B. BEFORE LIGHTING: SMELL ALL AROUND THE APPLIANCE
AREA FOR GAS. BE SURE TO SMELL NEXT TO THE FLOOR
BECAUSE SOME GAS IS HEAVIER THAN AIR AND WILL
SETTLE ON THE FLOOR.
WHAT TO DO IF YOU SMELL GAS
• DO NOT TRY TO LIGHT ANY APPLIANCE.
• DO NOT TOUCH ANY ELECTRIC 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.
C. USE ONLY YOUR HAND TO PUSH IN OR TURN THE GAS
CONTROL KNOB. NEVER USE TOOLS. IF THE KNOB WILL
NOT PUSH IN OR TURN BY HAND, DON’T TRY TO REPAIR
IT. CALL A QUALIFIED SERVICE TECHNICIAN. FORCE OR
ATTEMPTED REPAIR MAY RESULT IN A FIRE OR
EXPLOSION.
D. 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.
E. DO NOT OPERATE APPLIANCE UNLESS UNIT IS FILLED
WITH WATER AND WATER LINES ARE FULLY OPEN.
OPERATING INSTRUCTIONS
1.
2.
3.
4.
5.
6.
7.
STOP! READ THE SAFETY INFORMATION THE
NEXT STEP ABOVE ON THIS LABEL.
SET THE SYSTEM CONTROLLER TO THE LOWEST
SETTING.
TURN OFF ALL ELECTRIC POWER TO APPLIANCE.
THIS APPLIANCE IS EQUIPPED WITH AN IGNITION
DEVICE WHICH AUTOMATICALLY LIGHTS THE BURNER.
DO NOT TRY TO LIGHT THE BURNER BY HAND.
REMOVE CONTROL ACCESS PANEL.
REFER TO DIAGRAMS ABOVE. TURN TOP KNOB OF GAS
CONTROL CLOCKWISE
TO “OFF” POSITION, (FIG. A).
WAIT FIVE (5) MINUTES TO CLEAR OUT ANY GAS. THEN
SMELL FOR GAS, INCLUDING NEAR THE FLOOR. IF YOU
SMELL GAS,
STOP ! FOLLOW “B” IN THE SAFETY INFORMATION
ABOVE ON THIS LABEL.
IF YOU DON’T SMELL GAS, GO TO THE NEXT STEP.
8. TURN TOP KNOB OF GAS CONTROL COUNTERCLOCKWISE
TO “ON” POSITION, (FIG. B).
9. REPLACE CONTROL ACCESS PANEL.
10. TURN POWER SWITCH TO “ON” POSITION.
11. SET THE SYSTEM CONTROLLER TO DESIRED SETTING.
12. IF THE APPLIANCE WILL NOT OPERATE, FOLLOW THE
INSTRUCTIONS “TO TURN OFF GAS TO THE APPLIANCE”
AND CALL YOUR SERVICE TECHNICIAN OR GAS
SUPPLIER.
TO TURN OFF GAS TO APPLIANCE
4.
1. SET THE SYSTEM CONTROLLER TO THE LOWEST
SETTING.
2. TURN POWER SWITCH ON APPLIANCE TO “OFF”
POSITION.
3. REMOVE ACCESS PANEL TO EXPOSE GAS CONTROL.
5.
24
REFER TO DIAGRAMS ABOVE. TURN TOP KNOB OF GAS
CONTROL CLOCKWISE (TO “OFF” POSITION, (FIG. A).
REPLACE CONTROL ACCESS PANEL.
Lighting Instructions for the G(B/W) 1000 through 2500 models
FOR YOUR SAFETY READ BEFORE OPERATING
WARNING: IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY, A
FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE,
PERSONAL INJURY OR LOSS OF LIFE.
C. USE ONLY YOUR HAND TO TURN THE MAIN MANUAL GAS
VALVE HANDLE. NEVER USE TOOLS. IF THE HANDLE WILL
NOT TURN BY HAND, DON’T TRY TO REPAIR IT. CALL A
QUALIFIED SERVICE TECHNICIAN. FORCE OR ATTEMPTED
REPAIR MAY RESULT IN A FIRE OR EXPLOSION.
A. THIS APPLIANCE DOES NOT HAVE A PILOT. IT IS EQUIPPED
WITH AN IGNITION DEVICE WHICH AUTOMATICALLY
LIGHTS THE BURNER. DO NOT TRY TO LIGHT THE BURNER
BY HAND.
B. BEFORE LIGHTING: SMELL ALL AROUND THE APPLIANCE
AREA FOR GAS. BE SURE TO SMELL NEXT TO THE FLOOR
BECAUSE SOME GAS IS HEAVIER THAN AIR AND WILL
SETTLE ON THE FLOOR.
WHAT TO DO IF YOU SMELL GAS
• DO NOT TRY TO LIGHT ANY APPLIANCE.
• DO NOT TOUCH ANY ELECTRIC 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.
D. 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.
E. DO NOT OPERATE APPLIANCE UNLESS UNIT IS FILLED
WITH WATER AND WATER LINES ARE FULLY OPEN.
OPERATING INSTRUCTIONS
1.
2
3.
4.
5.
6.
STOP! READ THE SAFETY INFORMATION ABOVE ON
THIS LABEL.
SET THE SYSTEM CONTROLLER TO THE LOWEST
SETTING.
TURN POWER SWITCH ON APPLIANCE TO “OFF”
POSITION.
TURN MAIN MANUAL GAS VALVE TO “OFF” POSITION,
(FIGURE “B”). THE VALVE IS “OFF” WHEN THE HANDLE IS
PERPENDICULAR TO THE GAS FLOW DIRECTION.
THIS APPLIANCE IS EQUIPPED WITH AN IGNITION
DEVICE WHICH AUTOMATICALLY LIGHTS THE BURNER,
DO NOT TRY TO LIGHT THE BURNER BY HAND.
WAIT FIVE (5) MINUTES TO CLEAR OUT ANY GAS. THEN
SMELL FOR GAS, INCLUDING NEAR THE FLOOR. IF YOU
SMELL GAS,
7.
8.
9.
10.
STOP! FOLLOW “B” IN THE SAFETY INFORMATION
ABOVE ON THIS LABEL. IF YOU DON’T SMELL GAS, GO
TO THE NEXT STEP.
TURN MAIN MANUAL GAS VALVE TO “ON” POSITION,
(FIGURE “A”), THE VALVE IS “ON” WHEN THE HANDLE IS
PARALLEL TO THE GAS FLOW DIRECTION.
TURN POWER SWITCH TO “ON” POSITION.
SET THE SYSTEM CONTROLLER TO DESIRED SETTING.
IF THE APPLIANCE WILL NOT OPERATE, FOLLOW THE
INSTRUCTIONS “TO TURN OFF GAS TO THE APPLIANCE”
AND CALL YOUR SERVICE TECHNICIAN OR GAS
SUPPLIER.
TO TURN OFF GAS TO APPLIANCE
1. SET THE SYSTEM CONTROLLER TO THE LOWEST SETTING.
2. TURN POWER SWITCH ON APPLIANCE TO “OFF” POSITION.
3. TURN MAIN MANUAL GAS VALVE TO “OFF” POSITION, (FIGURE “B”). THE VALVE
IS “OFF” WHEN THE HANDLE IS PERPENDICULAR TO THE GAS FLOW DIRECTION.
25
CONTROL SYSTEM
These jumpers are pre-set at the factory and should only be
adjusted by a qualified service technician.
DESCRIPTION OF MULTI-STAGE FIRING SYSTEM
The Display Board allows the end user to monitor water temperature,
set-points, differentials, options, fault indications and error codes.
Display Board pushbuttons labeled "ADJUST", "SELECT" AND
"ENTER/RESET" enable the user to adjust set-points, differentials,
post-circulate time, reset the cycle count and reset the control
system during lock-out. Changes made to programmable features
are stored in non-volatile memory.
The Central Control Board (CCB) is responsible for staging the
Ignition Control Boards (ICB) and monitoring safety limit devices,
control of circulation pump, power vent, alarm output and IRI gas
valves (only on IRI models). The thermostat also resides on the
CCB with inputs available for inlet, outlet and tank temperature
probes as well as an input for a remote 24 VAC thermostat. The
CCB has a display interface which connects to the Display Board
to show system status and failures. The CCB also has a set of DIP
switches which allows the user to control several system
parameters. (See Figure 14.)
Each stage requires an Ignition Control Board (ICB) which is
responsible for controlling a combustion blower, hot surface igniter
and gas valve. Each ICB is capable of monitoring gas valve power,
gas valve relay, flame sense and igniter current. The ICB is
designed to communicate with the Central Control Board (CCB).
Each ICB consists of identical hardware and software. Each stage
ICB is made unique through the use of circuit board jumpers which
allow the user to control such variables as stage identification and
blower/igniter usage. (See Figure 15 for jumper configurations.)
DIA-SCAN II DISPLAY BOARD OPERATING PROCEDURES
The Display Board provides a user-friendly interface to the Central
Control Board. With the Display Board, the user can control
appliance functions and view the overall operating status of the
appliance. If an error condition occurs, the Display Board will indicate
the nature of the fault by illuminating a red LED. The display will
further define the fault by illuminating a red LED corresponding to
the stage on which the fault has occurred. Red and green LEDs
are associated with each stage to indicate either a fault or normal
operation. If the fault continues until the unit "locks out", the display
will show a three digit code in addition to the red LEDs. (See Table
19 for error code chart.) Under normal operating conditions, the
four digit LED display on the Display Board will continuously illustrate
the water temperature sensed at the inlet temperature probe. If dip
DIP SWITCH CONFIGURATION TABLE
SW1 OFF
A
B
C
ON
SW1
D
1 2 3 4 5 6 7 8
ABC DEFGH
E
F
G
H
Figure 14. Central Control Board's Dip Switch Configuration and Options
26
3 STAGE
3 TRIALS
NO IRI
GAS VALVE
INLET
ON
4 STAGE
1 TRIAL
IRI
GAS VALVE
TANK
SELECTION:
EITHER 3 OR 4 STAGE SYSTEM
EITHER 3 OR 1
WHETHER SYSTEM IS IRI OR
STANDARD
INLET OR TANK AS
CONTROLLING PROBE
NO EXTERNAL EXTERNAL
WHETHER EXTERNAL
THERMOSTAT THERMOSTAT THERMOSTAT IS USED
OUTLET 210°F OUTLET 240°F OUTLET MAXIMUM TEMPERATURE
190°F
220°F
MAX. SET-POINT TEMPERATURE
DEGREES °F DEGREES °C
EITHER °F OR °C FOR DISPLAYED
TEMPERATURE
Figure 15. Ignition Control Board Jumper Settings
Green Status Lights
switch "D" on the Central Control Board is placed in the "ON"
position, it will show the temperature at the tank probe. (See Figure
14.) The push buttons on the Display Board allow the user to
program and view several system parameters described in the
following text. The Display Board is connected to the Central Control
Board through a 6 conductor cable assembly with modular plug
terminations. In addition, an 8 conductor modular jack on the Display
Board allows for connecting a remote display board.
Green LEDs indicate when a given stage has sensed flame and is
in the heating state. They also are used to indicate when the
Set-Point differential for a given stage is being viewed or adjusted.
(See Figure 16.)
STAGE 1:
STAGE 2:
STAGE 3:
STAGE 4:
When power is applied to the Control System, the Display Board
will initially run through a self-diagnostic test, and then display the
inlet temperature. To display a specific setting or temperature,
press the SELECT push-button until the appropriate LED is
illuminated (see Figure 16). After 5 seconds, the Display Board
will automatically revert to displaying the Inlet temperature. Pressing the ENTER/RESET push-button will hold the display in the
indicated mode until the SELECT push-button is pressed.
Red Fault Lights
The Red LEDs are illuminated to show faults and help in trouble
shooting. There are three faults (High Gas Fail, LWCO and Power
Vent Fail) listed as "Optional" which are only functional when the
particular "Optional" equipment is included with the boiler. The red
stage LEDs indicate on which stage a given fault has occurred.
(See Figure 16.)
With the display board, the user can make adjustments to many of
the appliance’s control features. This includes the following:
Options/Features Setting Procedures
•
•
•
•
•
•
Stage One in Operation
Stage Two in Operation
Stage Three in Operation
Stage Four in Operation
Blocked Flue: Blockage in Flue
Probe Fail: One of the controlling Probes has failed
Insufficient Air: Not enough Air to Close Switch
Circulate Fail: Flow Switch Not Closed
Gas Valve Fail: Relay for Gas Valve in Incorrect State
High Limit: High Limit has been Exceeded
Flame Fail: No Flame Sensed upon Ignition
Igniter Fail: Igniter did not reach Minimum Amperage
Low Gas Fail: Gas Pressure too low to Close Switch
Set Appliance Stage Temperature Set-point Value
Set Appliance Stage Switching Differential Value
Select Appliance Post-Circulate Time
Check Appliance Cycle Count
View Last Error Encountered by Control
Control the water temperature in a storage tank
27
Figure 16. Display Board
Outlet Probe
The Outlet Temperature/ECO probe is located on the left side of the
header and has two sets of wires embedded in it. The black wires
sense the temperature at the probe. Their output is shown on the
display screen when the "OUTLET" LED is illuminated. The red
wires control the ECO (Emergency Cutoff) which shuts down the
unit if the water temperature exceeds 250°F (121°C) and requires
a manual reset of the boiler. The outlet probe functions as a
automatically resettable high limit and is not considered a controlling
probe on the boiler, which means it cannot be set to control the
staging of the unit. Depending on the application of the boiler, the
probe is set to one of two settings. In GW applications, the maximum
Outlet Set Point is 210°F (99°C) and in GB applications it is 240°F
(115°C). The Outlet probe Set Point can be adjusted between
these two values using Dip Switch "F" on the Central Control Board
inside the control box. (See Figure 14.)
High Gas Fail: Gas Pressure at Manifold too High
LWCO: Low water Cutoff activated. Not enough water.
Power Vent Fail: Not Enough Air to Close Switch
Stage One: Failure on Stage One
Stage Two: Failure on Stage Two
Stage Three: Failure on Stage Three
Stage Four: Failure on Stage Four
Yellow Parameter Set Lights
The five yellow parameter set lights allow the user to view system
set points and options. In conjunction with the four green stage
LEDs, the user can monitor and change settings on the various
stages. (See Figure 16.)
Inlet*:
Outlet:
Set-Point**:
Set-Point Differential:
Standby:
Temperature shown is Inlet Water
Temperature.
Temperature shown is Outlet Water
Temperature.
Indicated probe set-point is being
displayed.
Shows differentials of each stage.
Indicates Set-Point is Satisfied. Boiler
in Idle State.
To view the current programmed temperature set-point for the Outlet Temperature probe:
1.
Press the SELECT push-button on the display board until both
the Set-Pt LED and Outlet Water Temperature LED (see
Figure 16) are illuminated.
2.
The LED display will show the current set-point temperature.
Note:
*Defaults to tank probe temperature when Dip Switch "D" on
Central Control Board is Switched to the "ON" position.
(See Figure 14.)
Under no circumstances should the Outlet/ECO be set
to exceed 210°F (99°C) in applications where the boiler
is heating potable water. Failure to observe this will
void the warranty.
Inlet Probe
The Inlet probe is located on the right side of the Inlet/Outlet header.
It has one set of blue wires embedded in it which senses the
temperature at the probe. The Inlet Probe is considered a controlling
probe and can be used to control the staging of the unit. The inlet
probe set-point is fully adjustable between the factory set minimum
value of 80°F (25°C) and a user controlled maximum value which
will depend on unit's application. In GW applications, the maximum
Inlet Set-Point is 190°F (88°C) and in GB application it is 220°F
(104°C). The Inlet probe Set-Point can be adjusted between these
two maximum values using Dip Switch "G" on the Central Control
Board which is located inside the control box. (See Figure 14.)
**Shows set-point temperatures for Inlet/Tank or Outlet in
conjunction with yellow parameter lights. See temperature
probe section below.
TEMPERATURE PROBES
All units come with two temperature probes connected to the Inlet/
Outlet header. Additionally, an optional tank probe (thermistor type)
or 24V thermostat/aquastat can be connected to the unit. The probes
can be categorized as two types: controlling probes and safety
limit probes. Controlling probes can control the staging of the
boiler. Safety limit probes are used as resettable high limit switches.
The two controlling probes are the inlet probe and the tank probe.
The function and setting of the probes is further described in the
following sections.
To change or view the current programmed temperature set-point
for the Inlet Temperature probe value:
28
1.
2.
3.
4.
5.
6.
7.
Press the SELECT push-button on the display board until both
the Set-Pt LED and Inlet Water Temperature LED (see
Figure 16) are illuminated.
The LED display will show the current set-point temperature.
Press and hold the ADJUST push-button. The displayed
temperature will either increase or decrease. To alternate
between increasing or decreasing the temperature, release
then press and hold the ADJUST push-button.
When the desired set-point temperature is reached, release
the ADJUST push-button.
Press the ENTER/RESET push-button once, this enters the
selected set-point temperature into controller memory.
The appliance will now control the temperature to the desired
set-point value.
For setting the stage differentials, see the section labeled
Procedure for Setting Stage Differential.
NOTE:
be established. To facilitate proper operation and maximize
appliance performance, each stage has a programmable
operating switching differential or “hysteresis” about the set point.
This means a call for heat for a particular stage will become active
when the water temperature measured at the controlling
temperature sensing probe drops to the set-point value minus the
switching differential value. It is necessary to set three set-point
differential values for three stage units and four for four stage. The
burner will remain on until the water temperature measured at
controlling probe reaches the stage set-point value. The switching
differential value is fully programmable from 0° F to 20°F (0°C to
11°C) using the push-button(s) located on the Display Board.
To change or view the current programmed switching differential:
1.
The boiler must complete a full cycle in order for the
new setting to take effect. If the unit is turned off prior
to a complete cycle the setting will be lost and the
previous setting will remain in effect.
2.
3.
24 VAC System Controller (Optional)
A 24 VAC thermostat/aquastat can be implemented as a system
controller on Genesis units. The connection for such devices is
located in the 24 VAC junction box at the rear of the unit. A 24 VAC
thermostat/aquastat can only be used as an "On/Off" switch for the
unit. The actual controlling of the staging will be through either the
inlet or tank probe. To use a 24 VAC system controller, dip switch "E"
on the CCB must be switched to the "on" position. See Figure 14.
4.
5.
Tank Probe (Optional)
In addition to the Inlet and Outlet/ECO Probes, units can be
optionally equipped with a tank Probe. The connection for the tank
probe is located in the 24 VAC junction box at the rear of the unit.
The tank Probe can be configured to control the staging of the unit.
See Tank Probe Installation section on page 17 for additional
information.
6.
7.
Press the SELECT push-button on the display board until both
the Set-Pt Diff. and green Stage One LED (see Figure 16) are
illuminated.
The LED display will show the current differential for stage
one.
Press and hold the ADJUST push-button. The displayed value
will either increase or decrease. To alternate between
increasing or decreasing the differential, release then press
and hold the ADJUST push-button.
When the desired Set-Pt differential is reached, release the
ADJUST push-button.
Press the ENTER/RESET push-button once, this enters the
selected set-point deferential into controller memory. To view
the Set-Pt minus the Set-Pt differential, press and hold the
"ENTER" push-button. This will be the "turn-on" temperature
for Stage One and the "turn-off" temperature for Stage Two.
Repeat steps 2 through 5 for the rest of the stages.
The appliance will now control temperature utilizing the
desired differentials.
Example:
Application: Hydronic Heating
Desired System Temperature: 185°F (85°C)
Stage Differentials: 5°F (3°C) per Stage.
Procedure for Setting Tank Probe Temperature
Note: The user must first choose which probe is to control the
staging of the unit. The controlling probe will be either the inlet or
tank probe. (If the tank probe is used to regulate loop temperature
in hydronic applications (GB Models), make sure it is located on
the return side of the closed loop.) Use Dip Switch "D" on the
Central Control Board to make this selection. See Figure 14.
If you have a GW hot water supply boiler, and have installed the tank
probe, below are the instructions on how to adjust the water
temperature set-point.
1.
2.
3.
4.
5.
6.
7.
Press the SELECT push-button on the display board until both
the Set-Pt LED and Inlet Water Temperature LED (see
Figure 16) are illuminated.
The LED display will show the current set-point temperature.
Press and hold the ADJUST push-button. The displayed
temperature will either increase or decrease. To alternate
between increasing or decreasing the temperature, release
then press and hold the ADJUST push-button.
When the desired set-point temperature is reached, release
the ADJUST push-button.
Press the ENTER/RESET push-button once, this enters the
selected set-point temperature into controller memory.
The appliance will now control the temperature to the desired
set-point value.
For setting the stage differentials, see the section labeled
Procedure for Setting Stage Differential.
Set the stage differentials using the procedure described in the
Procedure for Setting Stage Differential section of the document.
Setting the control as described in the above example (5°F
differentials for each stage) will give the following stage set-points.
Stage One
Off Temperature: 185°F (85°C)
On Temperature: 180°F (82°C)
Stage Two
Off Temperature: 180°F (82°C)
On Temperature: 175°F (79°C)
Stage Three
Off Temperature: 175°F (79°C)
On Temperature: 170°F (77°C)
Stage Four
Off Temperature: 170°F (77°C)
On Temperature: 165°F (74°C)
Procedure for Setting Stage Differential
Once the system control and set-point temperature has been
entered, the switching differentials for the staging of the unit must
29
Procedure for Setting Pump Delay
The Controller is factory set with a 45 second post circulate function.
With the Display Board, the user has the capability to choose
between a 45, 90, or 180 second post circulate time period, or turn
the pump on continuously. This provides flexibility in selecting the
post circulate time to meet specific installation requirements, and
improves the efficiency of the circulating pump operation.
5.
6.
To change or view the current programmed post-circulating time:
1.
2.
3.
4.
5.
6.
Press the SELECT push-button on the display board until the
LED display reads "OP" (Options). See Figure 16.
To enter into the options mode, press the ENTER/RESET
push-button.
The display will illustrate "Crcu". Enter this mode by
pressing the ENTER/RESET push-button.
The display will now illustrate the current post circulate time.
Press the ADJUST push-button to select the desired post
circulate time (45, 90, 180, "con").
When you have selected the desired post circulate time mode,
press the ENTER/RESET push-button once, this enters the
selected post circulate time into controller memory.
The display will automatically return to illustrating the
controlling probe temperature after five (5) seconds.
Last Error Mode
In this mode, the Display Board will illustrate the last error which
caused the unit to "lock-out". When this mode is entered the three
digit failure code that was in memory last will be displayed.
(See table 19 for error codes.) For example, if the appliance
"locked-out" due to insufficient air on stage one, the display will
show 041. To enter into this mode, perform the following steps:
1.
2.
3.
4.
5.
Press the SELECT push-button on the display board until the
LED display reads "OP" (Options). See Figure 16.
To enter into the options mode, press the ENTER/RESET
push-button.
The display will illustrate "Crcu". Press the SELECT
push-button until the display illustrates "Ler". Enter this mode
by pressing the ENTER/RESET push-button.
The display will illustrate the last error detected by the control.
The display will automatically resort to illustrating the
controlling probe temperature after five (5) seconds.
Appliance Operating Sequence
1.
2.
3.
1.
2.
3.
4.
Press the SELECT push-button on the display board until the
LED display reads "OP" (Options). See Figure 16.
To enter into the options mode, press the ENTER/RESET
push-button.
The display will illustrate "Crcu". Press the SELECT
push-button until the display illustrates "CC". Enter this mode
by pressing the ENTER/RESET push-button.
The display will now illustrate the current number of cycles
stage one has fired. Notice that the green Stage One LED is
illuminated. Pressing the ENTER/RESET button again will
cause the green Stage Two LED to illuminate and the cycle
When power is applied to the control system, the Display Board
will initially run through a self-diagnostic routine, and then go
into its operating mode, displaying the temperature sensed
at the Inlet probe.
If the Central Control Board determines the actual water
temperature at the controlling temperature probe is below the
programmed temperature set-point minus the switching
differential, and the thermostat circuit or tank probe circuit is
closed, a call for heat is activated.
The control then performs selected system diagnostic checks.
This includes confirming the proper state of the ECO/High
Limit device, flow switch*, and pressure switches.
*Note: Correct water flow is vital to the operation of the boiler.
See table 4 in the Installation manual for requirements on flow,
head loss and heat exchanger pressure drop.
4.
5.
6.
7.
8.
Display Stage Cycle Count
The Central Control Board counts the number of cycles each stage
of the appliance has operated by counting how many times the gas
valve(s) are energized. To check the cycle count for each stage,
perform the following procedure:
count for stage two will be displayed on the screen. Cycle
counts for the other stages can be viewed in a similar fashion.
To reset the cycle count to zero, press the ADJUST pushbutton. Press the ENTER/RESET push-button to
successfully reset the cycle count. If the ENTER pushbutton is not pressed, the reset function will not be saved and
the original cycle count will continue to increment on
each gas valve operation.
The display will automatically return to illustrating the
controlling probe temperature after five (5) seconds.
9.
If all checks are successfully passed, the circulating pump
circuit is energized. Once the flow switch has closed, all
combustion blowers will energize for a 30 second pre-purge
cycle.
When the pre-purge cycle is complete, all blowers except stage
1 will drop out. Power is applied to the stage 1 ignitor element
for the ignitor warm-up period.
The control will verify ignitor current. After the verification, the
gas valve will open, allowing gas to enter the burner.
After an additional 1 second, the control will monitor the flame
sense probe to confirm a flame is present. If a flame is not
verified within 4 seconds, the gas valve is immediately closed.
The control will initiate an 15 second inter-purge period and
return to step 2, unless dip switch "B" is in the "ON" position,
see fig. 14, in which case it will proceed to "lock-out".
If a flame is confirmed, stage two will be activated. The blower
associated with stage two will start. Once the blower has
been proven, igniter two will begin its warm-up period.
(This is true on all units except the 1000 which has only one
igniter.) After the igniter current has been proven, stage two
will begin a trial for ignition.
Stage three will activate after flame is proven on stage two. If
applicable, the blower associated with stage three will begin.
Once the blower has been proven, a trial for ignition will begin
on stage three. If flame is not proven, there will be a 15
second interpurge on stages with an associated blower. The
boiler will then begin additional trials for ignition. On stages
without an associated blower, a five second delay will occur
before the gas valves are opened for additional trials for
ignition.
Note: Stages on which no blower or igniter is present will
bypass the blower and igniter proving periods. The gas valves will
open five seconds after a call for heat is initiated on the stage.
10. All stages will remain running until the set point for a given
stage is satisfied. If all stages are initiated, stage four will
30
NOTE: Cleaning of main burners.
drop out first followed by stages three, two and one. To achieve
maximum efficiency, stages will reignite if the system water
temperature drops below the stage Set Point minus the Set
Point Differential.
Shut off all gas and electricity to unit.
1. Remove main burners from unit.
Note: Once a stage is satisfied, the blower associated with that
stage will allow a 25 second postpurge before it deactivates.
2. Check that burner venturi and ports are free of foreign matter.
3. Clean burners with bristle brush and/or vacuum cleaner.
DO NOT distort burner ports.
11. Once all of the stages have been satisfied, the pump will run
for the programmed post-circulate cycle (factory default 45
seconds). See Procedure for Setting Pump Delay on page 30
of the manual.
12. The control now enters the idle state. This is indicated on the
display by the "Standby" LED. The control will continue to
monitor temperature and the state of other system devices. If
the water temperature at the designated system controller
drops below the set-point value minus the switching
differential, and the thermostat circuit or tank probe circuit
closes, the control will return to step 2 and repeat the entire
operating cycle. During this idle state, if the control detects an
improper operating state for external devices such as the ECO
switch, air pressure switch, gas pressure switch, etc., the
appropriate LED(s) on the Display Board will illuminate
indicating the nature of the fault.
4. Reinstall burners in unit. Ensure that all the screws on the
burner flange are tightened securely so that the gasket will
provide a good seal. Also, ensure that each orifice is centered
with the venturi opening of every burner. The washer of the
orifice must be inserted a minimum of 1/4" into the burner
tube. This is critical for proper operation. See Figure 18.
5. Also check for good flow of combustion and ventilating air to
the unit.
This is a powered burner and the flame is not supposed to be on
the burner. The flame should be just above the burner deck
approximately 1/8” and blue in color (see Figure 17).
Visually check flame characteristics through the view port located
under the left-hand header on the boiler. Figure 17 shows the
normal flame condition. Also, refer to the flame label on the unit
(adjacent to the view port).
PREVENTATIVE MAINTENANCE
These boilers are designed to give many years of efficient and
satisfactory service when properly operated and maintained. To
assure continued good performance, the following
recommendations are made.
The area around the unit should be kept clean and free from lint
and debris. Sweeping the floor around the boiler should be done
carefully. This will reduce the dust and dirt which may enter the
burner and heat exchanger, causing improper combustion and
sooting.
MAIN BURNERS
Check main burners every three months for proper flame
characteristics.
The main burner should display the following characteristics:
•
•
•
•
Provide complete combustion of gas.
Cause rapid ignition and carry over of flame across entire burner.
Give reasonably quiet operation during initial ignition, operation
and extinction.
Cause no excessive lifting of flame from burner ports
(see Figure 17).
Figure 18. Orifice Insertion
After placing the boiler in operation, check the ignition system safety
shut-off devices for proper operation. To accomplish this with the
main burners operating, close the valve on the manifold. Within
four seconds the main burners should extinguish. If this does not
occur immediately, discontinue gas supply by closing main manual
shut-off and call a qualified serviceman to correct the situation. If
the burners extinguish, then light boiler in accordance with lighting
and operating instructions.
If the preceding burner characteristics are not evident, check for
accumulation of lint or other foreign material that restricts or blocks
the air openings to the burner or boiler.
For installations above 4,500 feet (1350 m), refer to HIGH ALTITUDE
INSTALLATIONS in the installation section.
THE FLOW OF COMBUSTION AIR TO THE BOILER MUST NOT BE
OBSTRUCTED.
THE BOILER AREA MUST BE KEPT CLEAR AND FREE FROM
COMBUSTIBLE MATERIALS, GASOLINE AND OTHER FLAMMABLE
VAPORS AND LIQUIDS.
Figure 17. Normal Flame Characteristics
Any safety devices including low water cutoffs used in conjunction
31
1.
with this boiler should receive periodic (every six months) inspection
to assure proper operation. A low water cutoff device of the float
type should be flushed every six months. Periodic checks, at least
twice a year, should be made for water and/or gas leaks.
2.
3.
More frequent inspections may be necessary depending on water
conditions.
The boiler-mounted gas and electrical controls have been designed
to give both dependable service and long life. However, malfunction
can occur, as with any piece of equipment. It is therefore
recommended that all components be checked periodically by a
qualified serviceman for proper operation.
4.
5.
Turn off the electrical power, and manual gas shut-off.
•
Allow boiler parts to cool before disassembly.
Remove the vent pipe.
•
Check parts and chimney for obstructions and clean as
necessary.
Remove burners from boiler and other metal parts as required
to clean as necessary.
•
Refer to parts list supplied with this manual for
disassembly aid.
Clean and reinstall the parts removed in steps 2 and 3.
•
Be sure the vent pipe has a minimum upward pitch of 1/4"
per foot (2 cm/m) of length and is sealed as necessary.
Restore electrical power and gas supply to boiler.
•
Check for gas leaks and proper boiler and vent operation.
RELIEF VALVE
HEAT EXCHANGER PREVENTIVE MAINTENANCE
The safety relief valve should be opened at least twice a year to
check its working condition. This will aid in assuring proper
pressure relief protection. Lift the lever at the top of the valve several
times until the valve seats properly and operates freely.
In most water supply systems some solids exist. As the water is
heated, these tend to drop out depositing as scale or lime. This
scale must be removed before the heat exchanger tubes become
blocked.
CAUTION
DANGER
THE WATER PASSING OUT OF THE VALVE DURING CHECKING
OPERATION MAY BE EXTREMELY HOT. BEFORE OPERATING
RELIEF VALVE, MAKE SURE DRAIN LINE IS INSTALLED TO DIRECT
DISCHARGE TO A SAFE LOCATION SUCH AS AN OPEN DRAIN,
TO AVOID SCALDING OR WATER DAMAGE.
LIME ACCUMULATION CAN REDUCE THE LIFE OF THE
EQUIPMENT, REDUCE EFFICIENCY AND WASTE FUEL. BOILER
FAILURE DUE TO LIME OR SCALE BUILDUP VOIDS THE
WARRANTY.
DELIMING
WARNING
SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO
SHUT OFF, TURN OFF THE MANUAL GAS CONTROL VALVE TO
THE APPLIANCE.
The amount of calcium carbonate (lime) released from water is in
direct proportion to water temperature and usage. The higher the
water temperature or water usage, the more lime deposits are
dropped out of the water. This is the lime scale which forms in
pipes, boilers and on cooking utensils.
COMBUSTION AIR FILTER
If the combustion air supply to the boiler contains dust, dirt, drywall
dust etc. a filter must be installed. Air filter is not supplied with the
boiler as shipped from the factory. The installer must provide a
filtering system in the air inlet to the boiler if dust, dirt or construction
dirt can be pulled into the boiler through the inlet air piping.
The usage of water softening equipment greatly reduces the
hardness of water. However, this equipment does not always
remove all of the hardness (lime). For this reason it is recommended
that a regular schedule for deliming be maintained.
BLOWER COMPARTMENT
The time between cleaning will vary from two to six months
depending upon water conditions and usage. A change of
approximately 5oF (3°C) in the normal temperature rise through the
boiler is usually an indication that scale should be removed. For
long life, copper or brass is recommended for all valves, pipe and
fittings.
The blower compartment should be cleaned annually to remove
any dirt and lint that may have accumulated in the compartment or
on the blower and motor. Buildups of dirt and lint on the blower and
motor can create excessive loads on the motor resulting in higher
that normal operating temperatures and possible shortened service
life.
TUBE CLEANING PROCEDURE
MECHANICAL REMOVAL OF DEPOSITS
VENTING MAINTENANCE
Establish a regular inspection schedule, the frequency depends
on the local water conditions and severity of service. Do not let the
tubes clog up solidly. Clean out deposits over 1/16" (1.6 mm)
thickness.
It is recommended that the intake and exhaust piping of the
appliance be checked every 6 months for dust, condensate leakage,
deterioration and carbon deposits.
WARNING
To service heat exchanger tubes remove return header casting,
side opposite the water connections. Use a U.S. standard 5/8"
deep socket ratchet to remove the nuts, exposing the tube ends.
Inspect to ensure tubes are free of scale and deposits. If scaled,
remove deposits with a stiff wire brush or mechanical tube cleaner
to bare metal. Reinstall return header casting. Flush system.
DO NOT USE A NYLON BRUSH OR OTHER STATIC CREATING
MATERIAL TO CLEAN DUST AND CARBON DEPOSITS FROM
HEATING SURFACES AND VENT. SUCH DEPOSITS ARE
FLAMMABLE AND MAY BE IGNITED BY STATIC ELECTRICITY. USE
A METAL BRUSH TO MINIMIZE THE DANGER OF EXPLOSION.
Qualified serviceman should follow this procedure when the boiler's
intake and exhaust piping need cleaning:
Note: Removal of the heat exchanger is not required.
32
REPLACEMENT TUBES MUST BE PROPERLY INSTALLED AND
EXPANDED INTO THE ROLLED TUBE TUB.
Display Board contains sixteen (16) red fault LED indicators to
help pinpoint the source of failures. In addition, the display will
inform the user on which stage the failure occurred by illuminating
a red Stage LED. In cases where the problem persists to lockout,
the appropriate red LEDs will remain illuminated and a three digit
error code will flash on the display screen. A summary of error
codes is given in table 19. The error codes are broken into two
categories: hard lockouts and soft lockout.
OVER-ROLLING, MISALIGNMENT OF TUBES OR IMPROPER
TIGHTENING OF THE ASSEMBLY MAY RESULT IN LEAKS OR
DAMAGE TO THE HEAT EXCHANGER. CONTACT YOUR
A. O. SMITH DEALER FOR DETAILED INSTRUCTIONS.
Hard Lockouts:
Hard lockouts require a manual reset accomplished by pressing
the Enter/Reset push-button on the Display Board. Cycling the
power "OFF" and "ON" will not reset the control.
REPLACEMENT PARTS
Soft Lockouts:
Soft Lockouts also require a manual reset accomplished by
pressing the Enter/Reset push-button on the display board.
However, under a soft lockout condition, the control will re-initiate
an ignition process after one (1) hour provided the call-for-heat is
still present and will continue every hour until the unit is either reset
or ignites.
CAUTION
IF HEAT EXCHANGER MAINTENANCE REQUIRES TUBING
REPLACEMENT, SPECIAL PROVISIONS SHALL BE TAKEN TO
ENSURE THAT THE DAMAGED TUBES ARE CAREFULLY
REMOVED.
Replacement parts may be ordered through A. O. Smith dealers,
authorized servicers or distributors. Refer to the Yellow Pages for
where to call or contact (in United States) the A. O. Smith Water
Products Company, 5621 West 115th Street, Alsip, IL 60803,
1-800-433-2545 or (in Canada) A. O. Smith Enterprises Ltd., 768
Erie Street, Stratford, Ontario, Canada N5A 6T3, 519-271-5800.
When ordering parts be sure to state the quantity, part number and
description of the item including the complete model and serial
number as it appears on the product. Refer to the parts lists for
more information.
A description of the red fault LEDs and their corresponding
functions are as follows.
LED
For Technical Assistance call A. O. Smith Technical Information
Center at 1-800-527-1953.
Blocked Flue
Indicates a blockage or interference at the
appliance flue.
Temp. Probe Fail Indicates failure at one of the temperature
probes. Unit will "lock-out" only if controlling
probe fails.
Insufficient Air
Indicates air pressure was too low to create
a sufficient differential to close the
differential pressure switch.
Circulate Fail
Indicates water flow was too low to close
the flow switch.
Gas Valve Fail
Monitors Gas Valve relay output. LED is ON
when the output relay supplying power to
the gas valve(s) is open.
High Limit
Monitors ECO in the Outlet Temperature
probe. LED is ON when the ECO is open.
Flame Fail
Monitors the Flame Sense Rod. LED is ON
when a signal from the flame rod is not
sufficient to indicate flame.
Igniter Fail
Indicates igniter current was too low to meet
minimum value which allows trial for
ignition to continue.
Low Gas Fail
Inlet gas pressure is not sufficient to close
gas pressure switch.
High Gas Fail*
Manifold gas pressure is has exceeded
designed maximum value.
LWCO Fail*
Indicates water level in system is too low for
safe operation.
Power Vent Fail* Air pressure at Power Vent Switch is not
sufficient for safe operation.
TROUBLESHOOTING
Before any extensive troubleshooting, ensure that:
•
•
•
•
•
Power (120 VAC) is supplied to the appliance.
System control (tank probe, thermostat, etc.) is calling for
appliance operation (call for heat).
Other contacts (switches) are closed (low water cutoff, flow
switch, limit controls, pressure switches, etc.)
Gas supply pressure is within the maximum and minimum
operating ranges listed on the appliance rating plate/label.
Appliance is wired according to wiring diagram.
NOTE:
•
•
Controller Function
Shorting the thermostat wiring to ground in the 24 volt
circuit will blow the 3 amp fuse.
All wire terminals/connectors are firmly attached to valves,
modules, switches, limit controls, etc.
There has been no damage caused by freezing, inoperative
pumps, etc.
CAUTION
MAKE SURE POWER IS DISCONNECTED FROM MAIN BREAKER
BEFORE SERVICING.
CAUTION
LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN
SERVICING CONTROLS. WIRING ERRORS CAN CAUSE
IMPROPER FUNCTIONING OF UNIT RESULTING IN PROPERTY
DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.
*Optional Equipment - LEDs will illuminate only if equipment is
connected to boiler.
TROUBLESHOOTING IGNITION SYSTEM
Upon lockout, manually push the ENTER/RESET button on the
display panel to restart the boiler.
The control system has several features to aid in troubleshooting
problems which may occur during operation. If a fault occurs, the
Verify proper operation after servicing.
33
Table 19. Error Code Chart
GENESIS II CONTROL - FAULT OPERATION
FAULT
ERROR CODES
LOCKOUT
001
002
003
004
HARD
HARD
HARD
HARD
COMMUNICATIONS FAULT (CCB TO ICB)
STAGE 1:
STAGE 2:
STAGE 3:
STAGE 4:
ECO/HIGH LIMIT:
NO GAS VALVE POWER SENSED
STAGE 1:
STAGE 2:
STAGE 3:
STAGE 4:
LWCO
CIRCULATE FAULT (FLOW SWITCH)
010
HARD
011
012
013
014
020
030
HARD
HARD
HARD
HARD
HARD
SOFT
INSUFFICIENT AIR (AIR PRESSURE SWITCH)
STAGE 1:
STAGE 2:
STAGE 3:
STAGE 4:
BLOCKED FLUE
POWER VENT
041
042
043
044
060
070
SOFT
SOFT
SOFT
SOFT
SOFT
SOFT
IGNITER FAILURE
STAGE 1:
STAGE 2:
STAGE 3:
STAGE 4:
LOW GAS FAILURE
081
082
083
084
090
HARD
HARD
HARD
HARD
HARD
HIGH GAS FAILURE
STAGE 1:
STAGE 2:
STAGE 3:
STAGE 4:
101
102
103
104
HARD
HARD
HARD
HARD
GAS VALVE RELAY FAILURE
STAGE 1:
STAGE 2:
STAGE 3:
STAGE 4:
111
112
113
114
HARD
HARD
HARD
HARD
FLAME FAILURE
STAGE 1:
STAGE 2:
STAGE 3:
STAGE 4:
121
122
123
124
HARD
HARD
HARD
HARD
PROBE FAULTS
OUTLET PROBE
INLET PROBE
REMOTE PROBE
IRI GAS VALVE FAILURE
CPU FAULT
131
132
133
140
210
HARD
HARD
HARD
HARD
HARD
For additional information please refer to the User’s Manual supplied with the boiler or contact:
A.O. Smith Technical Services 7 a.m. to 7 p.m. Central Time at: 1-800-527-1953
Our Internet Site is another source of information 24 hours a day.
http://www.hotwater.com
34
NEW BOILER LIMITED WARRANTY
A. O. Smith Corporation, the warrantor, extends the following LIMITED WARRANTY to the owner of this hydronic boiler:
1.
If within TEN years after initial installation of the boiler, the heat exchanger shall prove upon examination by the warrantor to be defective in material
or workmanship, the warrantor, at his option, will exchange or repair such part or portion. This term is reduced to FIVE years if this boiler is used for
volume hot water supply purposes other than hydronic space heating.
a. This warranty is extended to the owner for all other parts or portion during the FIRST year following initial installation of this boiler.
b. The warranty on the repair or replacement of the part or portion will be limited to the unexpired term of the original warranty.
2.
CONDITIONS AND EXCEPTIONS
This warranty shall apply only when the boiler is installed in accordance with local plumbing and building codes, ordinances and regulations, the
printed instructions provided with it and good industry practices. In addition, an appropriately sized safety relief valve certified to the ASME Boiler
and Pressure Vessel Code must have been installed and fresh water used for filling and makeup purposes;
a. This warranty shall apply only when the boiler is used:
(1) at temperatures not exceeding the maximum setting of its operative and/or high limit control;
(2) at water pressure not exceeding the working pressure shown on the boiler;
(3) when filled with boiler water, free to circulate at all times and with the heat exchanger free of damaging scale deposits;
(4) in a noncorrosive and non-contaminated atmosphere;
(5) in the United States, its territories or possessions, and Canada;
(6) at a water velocity flow rate, not exceeding or below the Boiler's designed flow rates;
b. Any accident to the boiler, any misuse, abuse (including freezing) or alteration of it, any operation of it in a modified form will void this warranty.
3.
SERVICE AND REPAIR EXPENSE
Under this limited warranty the warrantor will provide only a replacement part. The owner is responsible for all other costs. Such costs may include
but are not limited to:
a. Labor charges for service removal, repair or reinstallation of the component part;
b. Shipping, delivery, handling, and administrative charges for forwarding the replacement part from the nearest distributor and returning the
claimed defective part to such distributor.
c. All cost necessary or incidental for any material and/or permits required for installation of the replacement.
4.
LIMITATIONS ON IMPLIED WARRANTIES
Implied warranties, including any warranty of merchantability imposed on the sale of this boiler under state law are limited to one (1) year duration
for the boiler or any of its parts. Some states or provinces do not allow limitations on how long an implied warranty lasts, so the above limitation may
not apply to you.
5.
CLAIM PROCEDURE
Any claim under the warranty should be initiated with the dealer who sold the boiler, or with any other dealer handling the warrantor’s products.
If this is not practical, the owner should contact:
U.S. Customers
A. O. Smith Water Products Company
5621 West 115th Street
Alsip, IL 60803
Telephone: 800 323-2636
a.
b.
6.
Canadian Customers
A. O. Smith Enterprises Ltd.
P. O. Box, 310 - 768 Erie Street
Stratford, Ontario N5A 6T3
Telephone: (519) 271-5800
The warrantor will only honor replacement with identical or similar parts thereof which are manufactured or distributed by the warrantor.
Dealer replacements are made subject to in-warranty validation by warrantor.
DISCLAIMERS
NO OTHER EXPRESS WARRANTY HAS BEEN OR WILL BE MADE ON BEHALF OF THE WARRANTOR WITH RESPECT TO THE BOILER OR THE
INSTALLATION, OPERATION, REPAIR OR REPLACEMENT OF THE BOILER. THE WARRANTOR SHALL NOT BE RESPONSIBLE FOR WATER DAMAGE,
LOSS OF USE OF THE UNIT, INCONVENIENCE, LOSS OR DAMAGE TO PERSONAL PROPERTY OR OTHER CONSEQUENTIAL DAMAGE. THE WARRANTOR
SHALL NOT BE LIABLE BY VIRTUE OF THIS WARRANTY OR OTHERWISE FOR DAMAGE TO ANY PERSONS OR PROPERTY, WHETHER DIRECT OR
INDIRECT, AND WHETHER ARISING IN CONTRACT OR TORT.
a. Some states or provinces do not allow the exclusion or limitation of the incidental or consequential damage, so the above limitations or exclusions
may not apply to you.
b. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state or province to province.
Fill in the following for your own reference. Keep it. Registration is not a condition of warranty. The model and serial number are found on the boiler’s
rating plate.
Owner_____________________________________________________________________________________________________________________
Installation Address___________________________________________________________________________________________________________
City and State or Province_____________________________________________________Postal/Zip Code____________________________________
Date Installed__________________________Model No.______________________________Serial No.________________________________________
Dealer’s Name_______________________________________________________________________________________________________________
Dealer’s Address________________________________________________________________Phone No. ____________________________________
FILL IN WARRANTY AND KEEP FOR FUTURE REFERENCE
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REPLACEMENT PARTS
5621 W. 115TH STREET, ALSIP, IL 60803
Phone: 800-433-2545 Fax: 800-433-2515
www.hotwater.com E-Mail: parts@hotwater.com
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