(211817-000) – PDF - AO Smith Water Heaters
Contents
1. THE WATER HEATER SHOULD BE LOCATED INAN AREA WHERE THE GENERAL PUBLIC DOES NOT HAVE ACCESS TO SET TEMPERATURES IT IS RECOMMENDED IN DOMESTIC HOTWATER 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 WILLALSO PROVIDE THE MOST ENERGY EFFICIENT OPERATION OF THE BOILER AND MINIMIZE SCALE FORMATION IN THE HEAT EXCHANGER THUS PROLONGING THE LIFE OF THE BOILER SETTING THE WATER HEATER TEMPERATURE AT 120 F 49 C WILL REDUCE THE RISK OF SCALDS SOME STATES PROVINCES REQUIRE SETTINGS AT SPECIFIC LOWER TEMPERATURES TABLE 1 BELOW SHOWS THE APPROXIMATE TIME TO BURN RELATIONSHIP FOR NORMAL ADULT SKIN TABLE 1 Risk of Scalds Time to Produce 2nd amp 3rd Degree Burns on Adult Skin Temperature Setting Over 170 F 77 C 160 F 71 C Nearly instantaneous About 1 2 second About 1 1 2 seconds Less than 5 seconds About 30 seconds More than 5 minutes 150 F 66 C 140 F 60 C 130 F 54 C 120 F 49 C or less 10 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 TROUBLESHOOTING AND MAINTENANCE The control system has several features to aid in troubleshooting problems which may occur during operation If a fault occurs the2. Note 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 the 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 1 To change or view the current programmed temperature set point for the Inlet Temperature probe value 1 Press the SELECT push button on the Display Board until both the Set Pt LED and Inlet Water Temperature LED are illuminated see Figure 4 The LED display will show the current set point temperature 3 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
3. 4 When the desired set point temperature is reached release the ADJUST push button 5 Press the ENTER RESET push button once this enters the selected set point temperature into controller memory 6 The appliance will now control the temperature to the desired set point value 7 For setting the stage differentials see the section labeled Procedure for Setting Stage Differential m NOTE 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 24VAC System Controller Optional A 24VAC thermostat aquastat can be implemented as a system controller on Genesis units The connection for such devices is located in the 24VAC junction box at the rear of the unit A 24VAC 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 24VAC system controller dip switch E on the CCB must be switched to the on position see Figure 1 Tank Probe Optional In additon 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 Procedure section below for additional
4. 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 2 The error codes are broken into two categories hard lockouts and soft lockout 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 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 A description of the red fault LEDs and their corresponding functions are as follows Also refer to Figure 4 Controller Function Blocked Flue Indicates a blockage or interference at the appliance flue Indicates failure at one of the temperature probes Unit will lockout only if controlling probe fails Indicates air pressure was too low to create a sufficient differential to close the differential pressur
5. 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 Date Installed Model No Serial No Dealer s Name Dealer s Address Phone No FILLIN WARRANTY AND KEEP FOR FUTURE REFERENCE 15 ProductPreservers REPLACEMENT PARTS JA Ce SATTA WATEH PRODUCTS COMPANY
6. Tao lae Hee LED1 ee CN90O OO CN10 F1 ON swaf DG addi 12345678 ABCDEFGH Figure 1 Dip Switch Configurations for Central Control Board INTERCOMMUNICATIONS CABLE 6 PIN CONNECTOR hs 232 MODEM CABLE 8 PINCONNECTOR DISPLAY PANEL CABLE CLL LILLE LLL ov SELECTION NO IRI GAS VALVE IRI GAS VALVE WHETHER SYSTEM IS IRI OR STANDARD PROBE EXTERNAL WHETHER EXTERNAL THERMOSTAT OUTLET 210 F OUTLET 240 F OUTLET MAXIMUM TEMPERATURE 190 F 220 F MAXIMUM INLET SET POINT TEMPERATURE DEGREES F DEGREES C EITHER F OR C FOR DISPLAYED TEMPERATURE ep ELE EE EE J26 J26 J26 J26 e AA J27 P J27 pg J27 J27 24 I li il e RED LED NO JUMPERS J26 JUMPE
7. corrosive atmospheres CIRCULATION PUMP Refer to the pump manufacturer s schedule of maintenance for frequency and method of lubricating the pump and motor Inspect the pump once a month for leaky mechanical seals and or O rings and loose or damaged components Contact a qualified service agent to replace or repair parts as required BLOCKED VENT SHUT OFF SYSTEM The boiler is equipped with a blocked vent shut off system which will close the gas valve and shut off the main burner gas when there is excessive pressure pressuring the vent system due to a partially or completely blocked vent The display on the front panel will indicate this failure condition DO NOT ATTEMPT TO OPERATE THE BOILER if this situation occurs Shut the boiler off before performing all the steps shown in TO TURN OFF GAS TO APPLIANCE section of the Lighting and Operating Instructions Contact a qualified service agent to inspect the unit and vent system and correct the problem VENT SYSTEM The flue products are corrosive in nature and if the boiler is vented horizontally the flue gases are at a higher pressure than the surrounding air pressure Inspection of the boiler and vent system is necessary to insure that flue gas leakage to the surrounding area does not occur Inspect the external surfaces of the vent system every 6 months for corrosion and leakage Inspect the vent terminations for corrosion and foreign matter including ice which may be blocking
8. information TANK PROBE INSTALLATION PROCEDURE GW Models Atank probe is supplied with each hot water supply boiler GW To connect the tank probe to the boiler remove the cover from the 24VAC junction box at the rear of the unit Connect the probe wires across terminals 1 amp 2 The wires leading to the terminals will be yellow Check the field connection diagram located below the junction box to assure proper wiring see Figure 5 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 advisabe to make sure Dip Switch F is set to the OFF position which sets the Outlet temperature Set Point to 210 F 99 C 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 Refer to Connection Diagram in the Installation Manual P N 211816 000 for wiring connection Procedure for Setting Tank Pro
9. 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 O 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 Press the SELECT push button on the Display Board until both the Set Pt Diff and green Stage One LED are illuminated see Figure 4 2 The LED display will show the current differential for stage one 3 Pressand 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 4 When the desired Set Pt differential is reached release the ADJUST push button 5 Press the ENTER RESET push button once this enters the selected set point differential 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 6 Repeat steps 2 through 5 for the rest of the stages 7 The appliance will now control temperature utilizing the desired differentials Example Application Hydronic He
10. ATIONS 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 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 Canadian Customers A O Smith Water Products Company A O Smith Enterprises Ltd 5621 West 115th Street P O Box 310 768 Erie Street Alsip IL 60803 Stratford Ontario N5A 6T3 Telephone 800 323 2636 Telephone 800 265 8520 a The warrantor will only honor replacement with identical or similar parts thereof which are manufactured or distributed by the warrantor b 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 MERCHANTABILITY OF 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
11. ENCE IGNITION CONTROLS INFORMATION TROUBLESHOOTING amp MAINTENANCE WARRANTY LA Co SOMO rad WATER PRODUCTS COMPANY ADIVISION OF A O SMITH CORPORATION EL PASO TX MC BEE SC RENTON WA STRATFORD ONTARIO VELDHOVEN THE NETHERLANDS www hotwater com PLEASE KEEP THESE INSTRUCTIONS ADJACENT TO BOILER AND PRINTED IN U S A 0802 NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE PART NO 211817 000 Lighting Instructions for the G B W 1000 through 2500 models FOR YOUR SAFETY READ BEFORE OPERATING EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE PERSONAL INJURY OR WARNING IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY A FIRE 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 BEFORE OPERATING SMELL ALL AROUND THE APPLI ANCE 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 ROBERTSHAW FIGURE B FIGURE A FLAMMABLE IF YOU CANNOT REACH YOUR GAS SUPPLIER CALL THEFIRE DEPARTMENT C USE ONLY YOUR HAND TO PUSH IN OR TURN THE GAS CONTROL KNOB NEVER USE TOOLS IF THE KNOB WILL NOT PUSH
12. IN OR TURN BY HAND DON T TRY TO REPAIR IT CALLAQUALIFIED SERVICE TECHNICIAN FORCE OR ATTEMPTED REPAIR MAY RESULT IN A FIRE OR EXPLOSION DONOTUSE 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 DO NOT OPERATE APPLIANCE UNLESS UNIT IS FILLED WITH WATER AND WATER LINES ARE FULLY OPEN WHITE RODGERS FIGURE A FIGURE B OFF POSITION ON POSITION ON POSITION Note Knob cannot be turned to OFF unless knob is pushed in slightly Do NOT force OPERATING INSTRUCTIONS 1 A STOP READ THE SAFETY INFORMATION THE NEXT STEP ABOVE ON THIS LABEL SET THE SYSTEM CONTROLLER TO THE LOWEST SETTING TURNOFF 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 FIGURE A WAITFIVE 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 INFORMA TION ABOVEON THIS LABEL IF YOU DON T SMELL GAS GO TO THE NEXT STEP TURN TOP KNOB OF GAS CONTROL COUNTER CLOCKWISE X TO ON POSITION FIG B REPLACE CONTROLACCESS PANEL TURN P
13. KED BLOWER BLOWER BLOWER BLOWER LWCO WATER ALARM IRIGAS LO GAS HI GAS1 HI GAS2 HI GAS3 HI_GAS4 ECO FLUE PROVER1 PROVER PROVER3 PROVER4 FLOW e Figure 3 Interface Board Components The Display Board allows the end user to monitor water temperature setpoints differentials options fault indications and error codes Display Board pushbuttons labeled ADJUST SELECT AND ENTER RESET enable the user to adjust setpoint differentials post circulate time reset the cycle count and reset the control system during lockout Changes made to programmable features are stored in nonvolatile memory Line Polarity Indicator A green LED is mounted on each Ignition Control Board to indicate line voltage polarity is properly connected see Figure 2 When 120VAC input power is properly connected to the Ignition Control Board the green LED will illuminate If an error is made when connecting 120VAC input power this LED will not light Fuse Protection The 24VAC 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 1 and 2 If the red LED is illuminated replace the fuse Repeated failure of the fuse is an indication of possible damage to the ignition control Note Four extra 3 amp fuses and one 5 amp fuse are supplied with the boiler Recommended Replacement fuses 3 Amp Littlefuse automotive f
14. LEL TO THE GAS FLOW DIRECTION TURN POWER SWITCH TO ON POSITION SETTHESYSTEM CONTROLLER TO DESIRED SETTING IFTHEAPPLIANCE WILL NOT OPERATE FOLLOW THE INSTRUCTIONS TO TURN OFF GAS TO THE APPLI ANCE AND CALL YOUR SERVICE TECHNICIAN OR GAS SUPPLIER TO TURN OFF GAS TO APPLIANCE 1 SETTHESYSTEM CONTROLLER TO THE LOWEST 3 TURN MAIN MANUAL GAS VALVE TO OFF POSITION SETTING FIGURE B THE VALVEIS OFF WHEN THE HANDLE 2 TURN POWER SWITCH ON APPLIANCE TO OFF IS PERPENDICULAR TO THE GAS FLOW DIRECTION POSITION WARNING THE UNIT SHOULD NOT BE INSTALLED DIRECTLY ON A CARPETED FLOOR AFIRE HAZARD MAY RESULT Instead the boiler must be installed on the A O Smith Combustible Floor Kit Base or concrete blocks extending beyond the full width and depth of the boiler by at least 3 inches 76 2 mm If the boiler is installed in a carpeted alcove the entire floor must be covered with concrete blocks or use the A O Smith Combustible Floor Kit Base FLAMMABLE ITEMS PRESSURIZED CONTAINERS OR ANY OTHER POTENTIAL FIRE HAZARDOUS ARTICLES MUST NEVER BE PLACED ON OR ADJACENT TO THE BOILER OPEN CONTAINERS OF FLAMMABLE MATERIAL SHOULD NOT BE STORED OR USED IN THE SAME ROOM WITH THE BOILER Light the unit in accordance with the instructions on the lighting and operating label attached to the boiler These instructions are repeated on the previous two pages OPERATING CONTROLS INFORMATION MULTI STAGE FIRI
15. LL THE FIRE DEPARTMENT USEONLY YOURHAND TO TURN THE MAIN MANUAL GAS VALVEHANDLE 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 DONOTUSE 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 DO NOT OPERATE APPLIANCE UNLESS UNIT IS FILLED WITH WATER AND WATER LINES ARE FULLY OPEN FIGURE BJ GAS FLOW CL GAS FLOW GAS VALVE OPERATING INSTRUCTIONS SMELL FOR GAS INCLUDING NEAR THE FLOOR IF YOU 1 STOP READ THE SAFETY INFORMATION ABOVE SMELL GAS 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 WAITFIVE 5 MINUTES TO CLEAR OUT ANY GAS THEN STOP FOLLOW B IN THE SAFETY INFORMA TION 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 PARAL
16. NG AND CONTROL SYSTEM ALL MODELS The control system consists of four basic components 1 Central Control Board 2 Ignition Control Board 3 Display Board 4 Interface Board see Figures 14 17 The Central Control Board Ignition Control Boards and the Interface Board 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 Interface 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 Central Control Board CCB is responsible for staging the Ignition Control Boards ICB and monitoring safety limit devices control of circulation pump power vent if installed 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 1 The Int
17. OWER SWITCH TO ON POSITION SET THE SYSTEM CONTROLLER TO DESIRED SETTING IFTHEAPPLIANCE 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 SET THE SYSTEM CONTROLLER TO THE LOWEST 4 REFER TO DIAGRAMS ABOVE TURN TOP KNOB OF SETTING GAS CONTROL CLOCKWISE TO OFF POSITION TURN POWER SWITCH ON APPLIANCE TO OFF FIGURE A POSITION REPLACE CONTROL ACCESS PANEL REMOVE ACCESS PANEL TO EXPOSE GAS CONTROL Lighting Instructions for the G B W 1000 through 2500 models FOR YOUR SAFETY READ BEFORE OPERATING FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE PERSONAL INJURY OR LOSS OF LIFE WARNING IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY A 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 BEFORE OPERATING 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 VALVE HANDLE FIGURE A FLAMMABLE IFYOUCANNOT REACH YOUR GAS SUPPLIER CA
18. R ONLY J27 JUMPER ONLY BOTH J26 amp J27 JUMPERS CN9 INDICATES IGNITER CONNECTED IGNITER CONNECTED NO IGNITER CONNECTED NO IGNITER CONNECTED 0o00 FUSE FAILURE BLOWER CONNECTED NO BLOWER CONNECTED BLOWER CONNECTED NO BLOWER CONNECTED CN40 med J LED2 Rows INTERCOMMUNICATIONS CABLE CN6 GREEN J25 JUMPER MUST BE IN PLACE ON THE FINAL ICB OF THE POLARITY CONTROL STRING THIS WILL CORRESPOND WITH STAGE 3 q PN LED ICB ON GB GW 1000 1500 AND STAGE 4 ICB ON GB GW 15 CN5 1850 2500 424 7 cT 1 2 SEC CN17 qae ab STAGE2 STAGE 3 J24 1B a2 J24 117312 CN4 da Gab seas Ssmo ss peu NO JUMPER JUMPER JUMPER JUMPER INSTALLED PINS TO6 PIN3TO4 PINT TO2 e CN1dooeh g Figure 2 Jumper Configurations for Ignition Control Board e ICB AND 9 e 9 PUMP FUSES o n a n n n 006 oto dg OBS GG cel ecol d ooo oOo o ORORO GG ooo 8 m CNI coel 6 lasal ecel eoo meal lo a OQ OS O60 a 000 O i TT MAIN POWER TB2 CN2 CN4 CN7 CN10 CONNECTIONS CN6 CNS W ou oa oa oa oa HU DO z z AEN aA 3 a s E 599 amp 2 2 ge CN9 Li LOW GAS AND F6 F4 F3 F2 F1 OPTIONAL ITEM Pump Staged Stage3 Stage Stage1 CONNECTIONS FN IRI LO HI HI HI HI K TB1 ALARM cas cas GAs 1 cas2 cass casa 3 H l mam 2 0 o e KM Ko areen L COMMON REMOTE POWER INLET OUTLET INDICATORS PUMP RELAY T STAT VENT TEMP TEMP CONNECTIONS mes m V Oo OQ o o Oo 2 oO o Oo Oo Oo Oo oO 9 o o o o o o o o o o o o o o TESTPORTS MANUAL BLOC
19. STANDBY O stace1 O sma O O smes O AA EXE DISPLAY CABLE STAGE STATUS LIGHTS Set Point differential for a given stage is being viewed or adjusted see Figure 4 STAGE 1 Stage One in Operation STAGE 2 Stage Two in Operation STAGE 3 Stage Three in Operation STAGE 4 Stage Four in Operation 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 connected to the boiler The red stage LEDs indicate the stage on which a given fault has occurred see Figure 4 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 on Ignition Igniter Fail Igniter did not reach Minimum Amperage Low Gas Fail Gas Pressure too low to Close Switch High Gas Fail Gas Pressure at Manifold too High LWCO Low water Cutoff activated Not enough water in system 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 t
20. STRUCTIONS These models have an automatic hot surface ignition system mounted on the combustion chamber panel inside the front jacket This hot surface igniter ignites the main burner gas whenever the system control calls for heat Before proceeding with operation of the unit make sure the boiler and system are filled with water and all air is expelled from the boiler radiator tank s and piping A WARNING THE MAIN MANUAL GAS SHUT OFF VALVE MUST HAVE BEEN CLOSED FOR AT LEAST FIVE 5 MINUTES BEFORE LIGHTING THIS WAITING PERIOD IS AN IMPORTANT SAFETY STEP ITS PURPOSE IS TO PERMIT GAS THAT MIGHT HAVE ACCUMULATED IN THE COMBUSTION CHAMBER TO CLEAR IF YOU DETECT GAS AT THE END OF THE PERIOD DO NOT PROCEED WITH LIGHTING RECOGNIZE THAT GAS ODOR EVEN IF IT SEEMS WEAK MAY INDICATE PRESENCE OF ACCUMULATED GAS SOMEPLACE IN THE AREA WITH A RISK OF FIRE OR EXPLOSION A WARNING THERE IS A RISK IN USING FUEL BURNING APPLIANCES SUCH AS GAS WATER BOILERS IN ROOMS GARAGES OR OTHER AREAS WHERE GASOLINE AND OTHER FLAMMABLE LIQUIDS ARE USED OR STORED 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 BOILER S MAIN BURNER FLAMES CAUSING FIRE OR EXPLOSION Some local codes permit operation of gas appliances if installed 18 inches or more above the floor This may reduce the risk if location in such an area cannot be avoided INDEX OPERATING SEQU
21. ZA 6 SMTA GAS FIRED COMMERCIAL COPPER BOILERS FOR HYDRONIC HEATING AND HOT WATER SUPPLY APPROVED 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 e 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 Installation and service must be performed by a qualified installer service agency or the gas supplier A WARNING SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF DO NOT TURN OFF OR DISCONNECT THE ELECTRICAL SUPPLY TO THE PUMP INSTEAD SHUT OFF THE GAS SUPPLY AT A LOCATION EXTERNAL TO THE APPLIANCE A WARNING DO NOT USE THIS BOILER IF ANY PART HAS BEEN UNDER WATER IMMEDIATELY CALL A QUALIFIED SERVICE TECHNICIAN TO INSPECT THE BOILER AND TO REPLACE ANY PART OF THE CONTROL SYSTEM AND ANY GAS CONTROL WHICH HAS BEEN UNDER WATER eeNeets A Q Smith Space Saver Gas Boiler User s Information Manual GB GW MODELS 1000 1300 1500 1850 2100 2500 SERIES 300 301 302 303 304 305 LIGHTING IN
22. al cycle count will continue to increment on each gas valve operation The display will automatically return to illustrating the controlling probe temperature after five b seconds Appliance Operating Sequence 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 controlling probe This can be either the inlet or tank probe If the ignition control determines the actual water temperature at the controlling temperature probe is below the programmed temperature setpoint 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 the Installation Manual P N 211816 000 for requirements on flow head loss and heat exchanger pressure drop 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 then applied to the stage 1 igniter element for the igniter warm up period The control will ver
23. ating Desired System Temperature 185 F 85 C Stage Differentials 5 F 3 C per Stage Note The user must 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 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 1 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 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 175 F 79 C 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
24. be Temperature The user can easily change or view the water temperature set point at any time by using the following procedure 1 Press the SELECT push button on the Display Board until both the Set Pt LED and Inlet Water Temperature LED are illuminated see Figure 4 2 The LED display will show the current set point temperature 3 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 4 When the desired set point temperature is reached release the ADJUST push button 5 Press the ENTER RESET push button once this enters the selected set point temperature into controller memory 6 The appliance will now control the temperature to the desired set point value 7 For setting the stage differentials see the section labeled Procedure for Setting Stage Differential Procedure for Setting Stage Differentials Once the system control and set point temperature has been entered the switching differentials for the staging of the unit must be established To facilitate proper operation and maximize appliance performance each stage has a programmable 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
25. ce schedule Use SAE 29 non detergent oil RELIEF VALVE 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 A 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 TOASAFE LOCATION SUCH AS AN OPEN DRAIN TO AVOID SCALDING OR WATER DAMAGE A WARNING SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF TURN OFF THE MANUAL GAS CONTROL VALVE TO THE APPLIANCE Table 2 Error Code Chart GENESIS Il CONTROL FAULT OPERATION ERROR CODES LOCKOUT 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 INSUFFICIENT AIR AIR PRESSURE SWITCH STAGE 1 STAGE 2 STAGE 3 STAGE 4 BLOCKEDFLUE POWER VENT IGNITER FAILURE STAGE 1 STAGE 2 STAGE 3 STAGE 4 LOW GAS FAILURE HIGH GAS FAILURE STAGE 1 STAGE 2 STAGE 3 STAGE 4 GAS VALVE RELAY FAILURE STAGE 1 STAGE 2 STAGE 3 STAGE 4 FLAME FAILURE STAGE 1 STAGE 2 STAGE 3 STAGE 4 PROBE FAULTS OUTLET PROBE INLET PROBE REMOTE PROBE IRI GAS VALVE FAILURE CPU FAULT For ad
26. ditional information please refer to the Owner 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 13 NOTES 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 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 safe
27. e switch Indicates water flow was too low to close the flow switch Monitors Gas Valve relay output LED is ON when the output relay supplying power to the gas valve s is open Monitors ECO in the Outlet Tempera ture probe LED is ON when the ECO is open Monitors the Flame Sense Rod LED is ON when a signal from the flame rod is not sufficient to indicate flame Indicates igniter current was too low to meet minimum value which allows trial for ignition to continue Inlet gas pressure is not sufficient to close gas pressure switch Manifold gas pressure has exceeded designed maximum value Indicates water level in system is too low for safe operation Air pressure at Power Vent Switch is not sufficient for safe operation Temp Probe Fail Insufficient Air Circulate Fail Gas Valve Fail High Limit Flame Fail Igniter Fail Low Gas Fail High Gas Fail LWCO Fail Power Vent Fail Optional Equipment LEDs will illuminate only if equipment is connected to boiler Upon lockout manually push the ENTER RESET button on the display panel to restart the boiler 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 excess
28. erface Board Figure 3 distributes power to the various components of the control system It also contains test points for the 24VAC devices in the safety circuit as well as fuses for each of the stage ICBs and the pump Along the bottom of the interface board several green LEDs show the state of various safety control devices during operation If the LED is illuminated the contact to the particular device is in its desired state To test the 24VAC signal of a device attach the positive terminal of a multimeter to the test port run the negative terminal to a suitable ground location and read the voltage Note Test ports are the metal terminals located below each of the green LEDs along the bottom of the board 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 2 for jumper configurations These jumpers are preset at the factory and should only be adjusted by a qualified service technician U4 G5555555555500 mE u1 oo TT Go g C1 fes fee
29. he user to view system set points and options In conjunction with the four green stage Encase field supplied wires between tank probe and junction box with 1 2 field supplied conduit Pigtails of field supplied wires should be spliced to pigtails of tank probe and connected to 24VAC junction box This conduit and wiring should be separate from any other conduit wiring to guard against EMI electromagnetic interference Figure 5 Tank Probe Installation LEDs the user can monitor and change settings on the various stages see Figure 4 Inlet Temperature shown is Inlet Water Temperature Outlet Temperature shown is Outlet Water Temperature Set Point Indicates controlling probe setpoint is being displayed Set Point Differential Standby Shows differentials of each stage Indicates Set Point is Satisfied Boiler in Idle State Defaults to tank probe temperature when Dip Switch D on Central Control Board is Switched to the ON position see Figure 1 TEMPERATURE PROBES All units come with two temperature probes connected to the Inlet Outlet header Additionally an optional tank probe thermistor type or 24VAC 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
30. ify igniter 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 sensing 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 a 15 second inter purge period and return to step 2 unless dip switch B is in the ON position in which case it will proceed to lockout If a flame is confirmed stage two will be activated The blower associated with stage two if applicable 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 af
31. ion 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 For installations above 4500 feet 1350 m refer to HIGH ALTITUDE INSTALLATIONS in the Installation Manual P N 211816 000 DO NOT STORE COMBUSTIBLE MATERIALS GASOLINE OR OTHER FLAMMABLE VAPORS LIQUIDS IN THE AREA OF THE APPLIANCE NONCOMPLIANCE MAY RESULT IN FIRE OR EXPLOSION DO NOT OBSTRUCT THE FLOW OF COMBUSTION OR VENTILATION AIR TO THE APPLIANCE CHEMICAL VAPOR CORROSION Boiler corrosion and component failure can be caused by airborne chemical vapors Spray can propellants cleaning solvents refrigerants calcium or sodium chloride water softener salts waxes chlorine and process chemicals are typical compounds that are potentially corrosive These materials are corrosive at very low concentration levels with little or no odor to reveal their presence Products of this sort should not be stored near the boiler Air which is brought in contact with the boiler should not contain any of these chemicals The boiler should be provided with air from outdoors when installed in environments having
32. ive lifting of flame from burner ports see Figure 6 LIGHT BLUE REGION DARK BLUE CONES BURNER VISUALLY CHECK FLAME THROUGH VIEW PORT ADJUST AIR SHUTTER TO OBTAIN A BLUE FLAME AS SHOWN FLAME SHOULD BE ABOVE THE BURNER APPROX 1 8 A Normal Flame Figure 6 Burner Flame Characteristics 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 NOTE Cleaning of main burners Shut off all gas and electricity to unit Allow boiler to cool Remove main burners from unit Check that burner venturi and ports are free of foreign matter Clean burners with bristle brush and or vacuum cleaner DO NOT distort burner ports 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 Bop e Note Make sure the washer of each pre jet orifice is inserted at least 1 4 into the burner tube and that it is not touching the sides of the burner tube This is critical for proper operation see Figure 7 Check for good flow of combustion and ventilating air to the unit BURNER TUBE ili ORIFICE WASHER ORIFICE BRACKET Figure 7 Burner Orifice Insertion 11 After placing the boiler in operation check the ignit
33. llow 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 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 4 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 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 e Set Appliance Stage Temperature Setpoint Value e Set Appliance Stage Switching Differential Value e Select Appliance Post Circulate Time e Check Appliance Cycle Count View Last Error Encountered by Control e Control the water temperature in a storage tank Green Status Lights Green LEDs indicate when a given stage has sensed flame and is in the heating state They also are used to indicate when the YELLOW PARAMETER SET LIGHTS O5ET PT DIFF oO
34. operation To change or view the current programmed post circulating time 1 Press the SELECT push button on the Display Board until the LED display reads OP Options see Figure 4 2 Toenterinto the options mode press the ENTER RESET push button 3 The display will illustrate Crcu Enter this mode by pressing the ENTER RESET push button 4 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 5 When you have selected the desired post circulate time mode press the ENTER RESET push button once this enters the time into controller memory 6 Thedisplay will automatically return to illustrating the controlling probe temperature after five 5 seconds Last Error Code 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 2 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 Press the SELECT push button on the Display Board until the LED display reads OP Options see Figure 4 2 To enter into the options mode press the ENTER RESET push button 3 The display will illustrate Crcu Press the SELECT push button until the display illustra
35. ter a call for heat is initiated on the stage 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 section on previous page The control now enters the idle state This is indicated on the display by the Standby LED The control will continuing to monitor temperature and the state of other system devices If the water temperature at the designated system controller drops below the setpoint 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 red LED s on the Display Board will illuminate indicating the nature of the fault Ay DANGER 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 A DANGER
36. tes Ler Enter this mode by pressing the ENTER RESET push button 4 The display will illustrate the last error detected by the control 5 The display will automatically resort to illustrating the controlling probe temperature after five b seconds 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 1 Press the SELECT push button on the Display Board until the LED display reads OP Options see Figure 4 2 To enter into the options mode press the ENTER RESET push button 3 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 4 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 count for stage two will be displayed on the screen Cycle counts for the other stages can be viewed in a similar fashion 5 Toresetthe cycle count to zero press the ADJUST push button 9 10 11 Press the ENTER RESET push button to successfully reset the cycle count If the ENTER push button is not pressed the reset function will not be saved and the origin
37. the exhausting flue products Call a qualified service agent to replace or repair any corroded or leaking parts Qualified service agent must inspect internal surfaces of the vent system and the boiler at least once a year DELIMING 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 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 The time between cleaning will vary from two to six months depending upon water conditions and usage A change of approximately 5 F 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 CAUTION LIME ACCUMULATION CAN REDUCE THE LIFE OF THE EQUIPMENT REDUCE EFFICIENCY AND WASTE FUEL BOILER 12 FAILURE DUE TO LIME OR SCALE BUILDUP VOIDS THE WARRANT Y COMBUSTION AIR BLOWER The bearings in the motor are pre lubricated and sealed at the factory The bearings should be oiled once every six months per the manufacturer s recommended maintenan
38. the inlet probe and the tank probe The function and setting of the probes is further described in the following sections 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 1 To view the current programmed temperature set point for the Outlet Temperature probe JUNCTION BOX REMOTE SENSOR WIRES YELLOW CONTROL BOARD 1 Press the SELECT push button on the Display Board until both the Set Pt LED and Outlet Water Temperature LED are illuminated see Figure 4 2 The LED display will show the current set point temperature
39. ty 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 attemperatures 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 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 LIMIT
40. use PN 257003 5 Amp Bussman Automotive fuse PN ATC5 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 DISPLAY SCREEN FRONT PANEL DISPLAY BLOCKED FLUE TEMP PROBE FAIL INSUFFICIENT AIR CIRCULATION FAIL GAS VALVE FAIL pum HIGH LIMIT RED FAULT LIGHTS FLAME FAIL IGNITER FAIL LOW GAS FAIL HIGH GAS FAIL LWCO FAIL POWER VENT FAIL SELECT Q Q ENTER RESET GENESIS II Figure 4 Display Board 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 Each stage has both a red and green LED associated with it 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 1 for error code chart Under normal operating conditions the four digit LED display on the Display Board will continuously show the water temperature sensed at the inlet temperature probe If dip switch D on the Central Control Board is placed in the ON position it will show the temperature at the tank probe see Figure 1 The push buttons on the Display Board a
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