A.O. Smith GB/GW-200 Boiler User Manual
Contents
1. Dealer s Address Phone No FILL IN WARRANTY AND KEEP FOR FUTURE REFERENCE 102. O Box 310 768 Erie Street Alsip IL 60803 Stratford Ontario N5A 6T3 Telephone 800 323 2636 Telephone 519 271 5800 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 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 Date Installed Model No Serial No Dealer s Name
3. This field supplied operating thermostat should be wired to the BROWN wires at the junction box The jumper at location J33 on the control board must NOT be on Refer to figures 2 and 3 for the location of this jumper Tank Probe Set Point Adjustment When tank probe is installed in a storage water tank and the tank probe is used with the WHC1502 system the controller will monitor and control the temperature of the water at the tank probe location Setting the tank probe set point temperature is accomplished through the Display Board control panel The standard program mable temperature range for the indirect water tank is 110 F to 190 F The switching differential of the probe is fixed at 5 F Tank Probe Temperature Set point Adjustment Procedure The user can easily change the tank probe 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 LED 15 see figure 1 and Inlet Wa ter Temperature LED LED 12 see figure 1 are illumi nated NOTE 3 When a tank probe is connected to the board atlocation CN10 the Inlet Water Temperature LED defaults to Tank Water Temperature 2 The LED display will show the current tank set point tem perature 3 Press and hold the ADJUST push button The displayed temperature will either increase or decrease To alternate between increasing or decreasing the temperature re lease then press and
4. Boiler s designed flow rates b 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 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 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
5. REMOVED FROM PINS Oo TRIAL FOR IGNITION oC CONTROL EORRD 1 TROUBLESHOOTING IGNITION SYSTEM Display Board LED Indicators The Display Board contains eleven 11 solid state LED indicators for viewing various states of appliance operation and for trouble shooting if problems occur Under normal operating conditions the appropriate LED s will sequence with steady illumination according to the particular appliance operating state In cases where prob lems or a lockout occurs the appropriate LED s will illuminate indi cating the general area where the problem exists A description of the LED s and their corresponding functions are as follows LED Call for Heat Flow Switch Pressure Switch Ignitor Current Gas Valve Flame Sense Blocked Inlet Blocked Flue Blower Fail Circulate Fail Ignition Fail Controller Function Monitors Outlet water temperature minus Switching Differential and thermostat circuit or tank probe circuit LED is ON when the tem perature at Outlet Water Probe is less than the set point minus the switching differential and the thermostat circuit or tank probe circuit is closed Monitors the condition of the flow switch LED is ON when the flow switch closes indicating water flow through the system Monitors the condition of the pressure switch s LED is ON when the pressure switch s are in their correct state Monitors current flow through the ignitor element LED is ON when current fl
6. 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 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
7. vapors Spray can propellants cleaning solvents refrigerants calcium or sodium chloride water softener salts waxes 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 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 NOTES 1 Use either the tank probe or an external control 24 VAC for system control but not both 2 If any of the original wire as supplied with the appliance must be replaced it must be replaced with 18 GAUGE 105 C wire or equivalent TANK PROBE GWS ONLY SEE NOTE 1 IGNITOR 932 2 LED 2D BLOWER NN lu ui NN 1219 aaa imn NN in NN JUNCTION m BOX BROWN BROWN EXTERNAL CONTROL 24 VAC THERMOSTAT SEE NOTE 1 OVA Oc 24 VAC TRANS MODE
8. CH HAS BEEN UNDER WATER DO NOT OPERATE APPLIANCE UNLESS UNIT IS FILLED WITH WATER AND WATER LINES ARE FULLY OPEN WHITE BADGER FIGURE A FIGURE OFF POSITION ON POSITION OPERATING INSTRUCTIONS BEEN 1 STOP READ THE SAFETY INFORMATION ABOVE ON THIS LABEL 2 SET THE SYSTEM CONTROLLER TO THE LOWEST SETTING 3 TURN OFF ALL ELECTRIC POWER TO APPLIANCE 4 THIS APPLIANCE IS EQUIPPED WITH AN IGNITION DEVICE WHICH AUTOMATICALLY LIGHTS THE BURNER DO NOT TRY TO LIGHT THE BURNER BY HAND 5 REMOVE CONTROL ACCESS PANEL 6 REFER TO DIAGRAMS ABOVE TURN TOP KNOB OF GAS CONTROL CLOCKWISE lt TO OFF POSITION FIG A 7 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 COUNTER CLOCKWISE TO ON POSITION FIG B 9 REPLACE CONTROL ACCESS PANEL 10 TURN POWER SWITCH TO ON POSITION SWITCH LIGHT COMES ON 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 1 SET THE SYSTEM CONTROLLER TO THE LOWEST SETTING 2 TURN POWER SWITCH ON APPLIANCE TO OFF POSITION SWITCH LIGHT GOES OUT 3 REMOVE ACCESS PANEL TO EXPOSE GAS CONTROL T
9. ERAL EE eis 1 LIGHTING INSTRUCTIONS 2 3 OPERATING SEQUENCE IGNITION CONTROL AND DIA SCAN II INSTRUCTIONS 4 8 MAINTENANCE 8 CONNECTION DIAGRAM 9 WARRANTY 10 LA Co 3D IL End WATEH PRODUCTS COMPANY A DIVISION OF SMITH CORPORATION EL PASO TX BEE SC RENTON WA STRATFORD ONTARIO VELDHOVEN THE NETHERLANDS www hotwater com PLEASEKEEP THESE INSTRUCTIONS ADJACENT TO BOILERAND NOTIFY OWNERTO KEEP FORFUTURE REFERENCE PRINTED IN U S A 2527 300 PART NO 210890 000 REV 1 SUPERSEDES PART NO 210311 000 THE UNIT SHOULD NOT BE INSTALLED DIRECTLY ON A CARPETED FLOOR A FIRE 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 76 2mm inches 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 following two pages Lighting Instruct
10. IA SET THE SYSTEM CONTROLLER TO THE 3 TURN MAIN MANUAL GAS VALVE TO OFF LOWEST SETTING POSITION FIGURE B THE VALVE 2 TURN POWER SWITCH ON APPLIANCE TO IS OFF WHEN THE HANDLE IS PERPEN OFF POSITION SWITCH LIGHT GOES OUT DICULAR TO THE GAS FLOW DIRECTION ELECTRONIC HOT SURFACE IGNITION CONTROL BOARD ALL MODELS The WHC1502 ignition control board is a fully integrated state of the art electronic control system The ignition control board includes a microprocessor which governs all temperature and ignition control functions for the appliance Inherent in the design are the normal operating sequences and safety features associated with a gas ignition control system The ignition control continuously performs various diagnostic tests to verify proper appliance and control operation Should an unsafe condition occur the control will shut down the burner and illuminate the appropriate diagnostic indicators on the Display Board indicating a need for service All operating programs are stored in permanent memory on the ignition control and a second programmable memory is used for retaining user specific operating parameters in the event main power is ever interrupted Line Polarity Indicator A green LED is mounted on the ignition control to indicate line volt age polarity is properly connected When 120 VAC input power is properly connected to the Ignition Control Board the green LED will illuminate If an error i
11. LS 200 300 400 amp 500 GAS VALVE MODELS NATURAL 650 amp 750 GAS VALVE PRIMARY ALARM OPTIONAL ALARM OPTIONAL ORANGE E PUMP 1 3 HP MAX PWR SWITCH BLACK BLACK WHITE WHITE BLACK EN GAS VALVE SECONDARY DISPLAY BOARD REMOTE DISPLAY EXT MODEM OPTIONAL NR BURKAY GENESIS CONNECTION DIAGRAM INTER CONNECT CABLE 9 i Br 9 SEE NOTE 1 TO TANK PROBE FROM JUNCTION BOX BLUE WHITE Ju INLET TEMP BLUE ORANGE ECO OUTLET TEMP BLOCKED INTAKE BLUE i SEE NOTE 1 d TO EXTERNAL CONTROL 24 VAC T STAT FROM J BOX BLOCKED 5 E WHITE FLUE YELLOW YELLOW ES J33 JUMPER ON OPERATION BLOWER EE WITH TANK PROBE PROVER SUPPLIED WITH GW BOILER AMP FUSE 0 GREEN miii J30 YELLOW EE JUMPER ON 1 TRIAL FOR IGNITION D eoa WIRING LEGEND GREEN i FACTORY INSTALLED YELLOVV MODELS FIELD INSTALLED PROPANE 650 amp 750 120 VAC GAS VELO GREEN FIGURE 3 POINT TO POINT WIRING DIAGRAM 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
12. NSTRUCTIONS 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 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 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 Ax 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 PAGE GEN
13. O TURN OFF GAS TO APPLIANCE 4 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 650 and 750 models FOR YOU EAD BEFOR ERATING Mir WARNING IF YOU DO NOT FOLLOW THESE INSTRUCTIONS o EXACTLY A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE PERSONAL INJURY OR LOSS OF LIFE FLAMMABLE A THIS APPLIANCE DOES NOT HAVE A PILOT IT C USE ONLY YOUR HAND TO TURN THE MAIN IS EQUIPPED WITH AN IGNITION DEVICE WHICH MANUAL GAS VALVE HANDLE NEVER USE AUTOMATICALLY LIGHTS THE BURNER DO NOT TRY TOOLS IF THE HANDLE WILL NOT TURN BY TO LIGHT THE BURNER BY HAND ZEE HAND DON T TRY TO REPAIR IT CALL A BEFORE LIGHTING SMELL ALL AROUND THE APPLI QUALIFIED SERVICE TECHNICIAN FORCE OR ANCE AREA FOR GAS BE SURE TO SMELL NEXT TO ATTEMPTED REPAIR MAY RESULT IN FIRE THE FLOOR BECAUSE SOME CAS IS HEAVIER THAN OR EXPLOSION AIR AND WILL SETTLE ON THE FLOOR D DO NOT USE THIS APPLIANCE IF ANY PART WHAT TO DO IF YOU SMELL GAS HAS BEEN UNDER WATER IMMEDIATELY CALL A QUALIFIED SERVICE TECHNICIAN TO DO NOT TRY TO LIGHT ANY APPLIANCE INSPECT THE APPLIANCE AND TO REPLACE DO NOT TOUCH ANY ELECTRIC SWITCH ANY PART OF THE CONTROL SYSTEM AND ANY DO NOT USE ANY PHONE IN YOUR BUILDING e IMMEDIATELY CALL YOUR CAS SUPPLIER FROM GAS CONTROL WHICH HAS BEEN UNDER WATER A NEIGHBOR S PH
14. ONE FOLLOW THE GAS SUPPLIER S INSTRUCTIONS DO NOT OPERATE APPLIANCE UNLESS UNIT IF YOU CANNOT REACH YOUR GAS SUPPLIER pel BNE LINES CALL THE FIRE DEPARTMENT VALVE HANDLE FIGURE FIGURE GAS FLOW GAS FLOW LT MAIN MANUAL CAS VALVE ON POSITION OFF POSITION OPERATING INSTRUCTIONS 1 STOP READ THE SAFETY STOP FOLLOW B IN THE SAFETY INFORMATION ABOVE ON THIS LABEL INFORMATION ABOVE ON THIS LABEL SET THE SYSTEM CONTROLLER TO THE MEM LOWEST SETTING TURN POWER SWITCH ON APPLIANCE TO AE MANUAL GAS VALVE TOS DN Ti POSITION FIGURE A THE VALVE IS ON OFF POSITION SWITCH LIGHT GOES OUT WHEN THE HANDLE IS PARALLEL TO THE GAS TURN MAIN MANUAL GAS VALVE TO OFF FLOW DIRECTION POSITION FIGURE B THE VALVE IS OFF WHEN THE HANDLE IS PERPEN TURN POWER SWITCH TO ON POSITION DICULAR TO THE GAS FLOW DIRECTION SWITCH LIGHT COMES ON S THIS APPLIANCE IS EQUIPPED WITH AN SET THE SYSTEM CONTROLLER TO IGNITION DEVICE WHICH AUTOMATICALLY DESIRED SETTING LIGHTS THE BURNER DO NOT TRY TO LIGHT THE BURNER BY HAND IF THE APPLIANCE WILL NOT OPERATE FOLLOW THE INSTRUCTIONS TO TURN OFF WAIT FIVE 5 MINUTES TO CLEAR OUT ANY GAS THEN SMELL FOR GAS INCLUDING GAS TO THE APPLIANCE AND CALL YOUR NEAR THE FLOOR IF YOU SMELL GAS SERVICE TECHNICIAN OR GAS SUPPLIER TO TURN OFF GAS TO APPL
15. SenSE FAIL Flame sense detected before gas valve is turned on SenSor FAIL One of the sensors Flow Pressure Hi Gas or Lo Gas was not in the correct state Ignitor FAIL No Ignitor current sensed No Ignition Flame not detected after 1 or 3 tries ECO FAIL ECO High Limit switch opened Control FAIL Relay did not open or close properly 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 in the vent system due to a partially or completely blocked vent system The DIA SCAN II 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 3 months for corrosion and leakage Inspect the vent terminations for corrosion and foreign matter which may be bloc
16. T HAVE ACCESS TO SET TEMPERATURES It is recommended 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 water heater and minimize scale formation SETTING THE WATER HEATER TEMPERATURE AT 120 F WILL REDUCE THE RISK OF SCALDS Some states 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 Temperature Time to Produce 2nd amp 3rd Setting Degree Burns on Adult Skin Over 170 F Nearly instantaneous 160 F About 1 2 second 150 F About 1 1 2 seconds 140 F Less than 5 seconds 130 F About 30 seconds 120 F or less More than 5 minutes DANGER o0 Lj TANK PROBE JUMPER J33 IS ON AS DEFAULT READY FOR USE WITH TANK PROBE SUPPLIED WITH THE BOILER GW MODELS ONLY SEE FIGURE 3 FOR CONNECTION DIAGRAM MOST ELECTRONIC SLOAN FOR CLARITY FOR STANDARD TANK CONTROLS e g 24 VAC HONEYWELL AQUASTAT REMOVE THIS JUMPER AND CONNECT THE CONTROL TO THE BROWN WIRES IN THE JUNCTION BOX ON THE BACK OF THE BOILER POWER LED GREEN un aa JUMPER ON OPERATION WTH TANK PROBE X R Ln SUPPLIED GWEOILER FUSE LED RED B 4 JUMPER DUMPERCON qm rns Ll
17. ZA Co SWOT GAS FIRED COMMERCIAL COPPER BOILERS FOR HYDRONIC HEATING AND HOT WATER SUPPLY USER S INFORMATION MANUAL 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 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 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 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 A GENI A Q Smith Space Saver Gas Boiler GB GW 200 300 400 500 650 750 SERIES 200 201 202 203 LIGHTING I
18. hold the ADJUST push button 4 When the desired set point temperature is reached re lease the ADJUST push button 5 Press the ENTER RESET push button once this enters the selected tank set point temperature into controller memory 6 The appliance will now control the tank water temperature to the desired set point value Ifthe ADJUST push button is held down long enough the set point will reach 110 F the minimum value or 190 F the maximum value and stop Atthis point if the desired set point is not obtained re lease the ADJUST push button and depress it again The set point value will now restart at 110 F 190 F and once again increase decrease in value for as long as the ADJUST push button is pressed Diascan Il cable connection point Top View Side View Figure 2 WHC 1502 Ignition Control Board 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 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 THE WATER HEATER SHOULD BE LOCATED IN AN AREA WHERE THE GENERAL PUBLIC DOES NO
19. imum value and stop At this point if the desired set point is not obtained re lease the ADJUST push button and depress it again The set point value will now restart at 110 F 240 F and once again increase decrease in value for as long as the ADJUST push button is pressed Switching Differential Adjustment Procedure To facilitate proper operation and maximize appliance performance the control has a programmable operating switching differential or hysteresis about the set point This means a call for heat will become active when the water temperature measured at the outlet temperature sensing probe Probe 1 drops to the set point value minus the switching differential value The burner will remain on until the water temperature measured at probe 1 reaches the set point value The switching differential value is fully programmable from 5 F to 50 F using the push button s located on the Display Board The default is set at 20 F To change or view the current programmed switching differential 1 Press the SELECT push button on the display board until the Set Pt differential LED LED 16 see figure 1 is illumi nated 2 The LED display will show the current switching differential Press and hold the ADJUST push button The displayed value will either increase or decrease To alternate between increas ing or decreasing the switching differential release then press and hold the ADJUST push button 4 When the desired
20. ions for the G B W 200 through 500 models FOR YOUR SAFETY READ BEFORE OPERATING WARNING 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 LIGHTING 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 F YOU CANNOT REACH YOUR GAS SUPPLIER CALL THE FIRE DEPARTMENT ROBERTSHAW FIGURE A FIGURE B OFF POSITION ON POSITION IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE PERSONAL INJURY OR LOSS OF LIFE FLAMMABLE 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 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 WHI
21. king 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 BURNER SYSTEM To maintain safe operation and the greatest efficiency for the boiler observe the burner flame through the observation port on the left jacket panel once a month for proper flame characteristics The burners should display the following characteristics Provide complete combustion of gas Causerapid ignition and carry over across all burners and across the entire burner e Give quiet operation during ignition burning and extinction Cause no excessive lifting of flames from the burner ports If the preceding characteristics are not evident check for accumulation of lint or other foreign material that restricts the inlet air or burner ports Ensure there is the proper amount of air to the burner Flame lifting from the burner is caused by too much air to the burner The burners must be inspected by a qualified service technician at least once a year 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 COM BUSTION OR VENTILATION AIR TO THE APPLIANCE CHEMICAL VAPOR CORROSION Boiler corrosion and component failure can be caused by airborne chemical
22. lay a specific setting or temperature press the SELECT push button until the appropriate LED is illumi nated see figure 1 After 5 seconds the Display Board will auto matically revert to displaying the Outlet 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 Temperature Set point Value e Set Appliance Switching Differential Value Select Appliance Post Circulate Time e Set Appliance Circulating Pump to Continuous ON Mode e Check Appliance Cycle Count Controlthe water temperature in a storage tank 1502 DISPLAY BOARD SELECT ENTER RESET Figure 1 Dia Scan Il Display Board Green Status Lights LED 1 Call for Heat LED2 Flow Switch LED 3 Pressure Switch LED 4 Ignitor Current LED 5 Gas Valve LED 6 Flame Sense Red Fault Lights LED 7 Ignition Fail LED 8 Circulate Failure LED 9 Blower Failure LED 10 Blocked Inlet LED 11 Blocked Flue Water Temperature Set Lights LED 12 Inlet Water Temperature LED 13 Outlet Water Temperature LED 14 Inlet Outlet Differential Temperature LED 15 Set Point Temperature LED 16 Outlet Set Point Differential Temperature Defaults to tank probe temperature when tank probe is used Temperature Set p
23. oint Adjustment Procedure The control board has a standard programmable temperature set point range of 110 F to 240 F The user can easily change the temperature set point at any time by using the following procedure In all cases the boiler must be energized The factory default set ting is 180 F To change or view the current programmed temperature set point value 1 Press the SELECT push button on the display board until both the Set Pt LED LED 15 see figure 1 and Outlet Water Tem perature LED LED 13 see figure 1 are illuminated 2 TheLED display will show the current set point temperature 3 Press and hold the ADJUST push button The displayed tem perature 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 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 If the ADJUST push button is held down long enough the set point will reach 110 F the minimum value or 240 F the max
24. ow through the ignitor is sensed Monitors Gas Valve output LED is ON when the output relays supplying power to the gas valve s is closed Monitors the Flame Sense Rod LED is ON when a signal from the flame rod is sufficient to indicate flame Indicates a blockage or interference at the ap pliance air inlet Indicates a blockage or interference at the ap pliance flue Indicates an error malfunction in the blower motor circuit Indicates an error malfunction in the circulating pump circuit Indicates a malfunction in the ignition system circuit Troubleshooting The WHC1502 Series Control System has many inherent diagnos tic and fault detection routines built into its operating hardware and software These routines in conjunction with the four 4 digit LED display and eleven 11 LED status indicators on the Display Board can greatly assist any service person in quickly pinpointing the source of a problem which may occur within the appliance Under certain circumstances multiple LED s will illuminate to better pinpoint the target area s The following list defines the error code messages that scroll across the LED display ERROR MESSAGE OPEn InLEt ProbE REPORTED ERROR No probe detected at connec tor CN1 on Control Board OPEn OutLEt ProbE No probe detected at connec tor CN2 on Control Board Circulation FAIL No flow detected at flow switch Inducor FAIL No pressure detected at pres sure switch FLAmE
25. pre purge cycle 5 When the pre purge cycle is complete the ignitor is ener gized The pump and blower should continue to run 6 The ignition control board will verify ignitor current After the verification the gas valve will open allowing gas to enter the burner T After an additional 1 second the ignition control board 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 and the ignition control board will return to step 2 unless jumper J30 is in place ON see figure 2 8 If a flame is confirmed the control will enter the heating mode where it will continue heating until the set point tem perature is reached and the thermostat circuit opens At that point the gas valve is closed and the control enters the post purge and post circulating cycles 9 The combustion blower will run for a 25 second post purge cycle When the post purge cycle is complete the blower is de energized and will coast to a stop The circulating pump will continue with the post circulate cycle for the selected amount of time factory default is 45 seconds See circulating pump adjustment procedure on page 5 and 6 of this manual 10 The control now enters the idle state while continuing to monitor temperature and the state of other system de vices If the outlet temperature drops below the set point value minus the switching differential and the thermosta
26. ressure Sense PreP Pre Purge state IGnt Ignitor Warm up rEdn Turn ON redundant Gas Valve relay lAct Turn ON Gas Valves StAb Turn OFF Ignitor and wait for Flame Sense Stabilization HEAt Heat Mode PoPC Post Purge and Post Circu late PoC Post Circulate Display Total Cycle Count The Main Control Board counts the number of cycles the appliance has operated In the Main Control Board a cycle is counted every time the gas valve is energized To access this number perform the following procedure 1 Press the SELECT push button on the display board until the LED display reads OPt Options 2 Toenterinto the options mode press the ENTER RESET push button 3 The display will illustrate Circ Press the SELECT push but ton until the display illustrates Count Enter this mode by press ing the ENTER RESET push button 4 Thedisplay will now illustrate the current number of cycles the appliance has cycled through 5 The display will automatically resort to illustrating the outlet tem perature TANK PROBE INSTALLATION PROCEDURE A tank probe is supplied with each hot water supply boiler When installed on a tank the inlet water temperature on the Dia Scan II will default to the tank temperature See figures 2 and 3 to add the tank jumper to the control board so that the tank probe is active A tank probe is NOT supplied with the hydronic heating boilers GB s Therefore a loop or operating thermostat must be provided
27. s made when connecting 120 VAC input power this LED will not light Improperly connecting the input power may result in a false flame sensor failure Fuse Protection The 24 VAC circuitry is protected with a 3 amp auto fuse If the fuse opens a red LED located near the fuse will light If the red LED is illuminated replace the fuse recommended replacement part is Little fuse p n 257003 automotive fuse Repeated failure of the fuse is an indication of possible damage to the ignition con trol board NOTE One extra fuse is supplied with the boiler Typical Control Appliance Operating Sequence 1 When power is applied to the WHC1502 ignition control the Display board will initially run through a self diagnostic routine and then go into its operating mode displaying the temperature sensed at temperature probe 1 Out let 2 If the ignition control board determines the actual outlet water temperature at the temperature sensing probe probe 1 is below the programmed temperature set point less the switching differential and the thermostat circuit or tank probe circuit closes call for heat is activated 3 The ignition control board then performs selected system diagnostic checks This includes confirming the proper state of the ECO High Limit device flow switch and pres sure switches 4 If all checks are successfully passed the circulating pump circuit is energized then the combustion blower is ener gized for the 20 second
28. switching differential is reached release the ADJUST push button 5 Press the ENTER RESET push button once this enters the selected switching differential value into controller memory 6 appliance will now control temperature utilizing the de sired switching differential value Ifthe ADJUST push button is held down long enough the switching differential setting will reach 5 the minimum value or 50 the maxi mum value and stop Atthis point if the desired switching differen tial is not obtained release the ADJUST push button and depress it again The switching differential value will now restart at 5 50 and once again increase decrease in value for as long as the ADJUST push button is pressed Circulating Pump Adjustment Procedure The Controller is factory set with a 45 second post circulate func tion Using 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 application requirements and improves the efficiency of the circulating pump 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 OPt Options 2 Toenter into the options mode press the ENTER RESET push button 3 The display will illustrate Circ Enter this mode by pressing
29. t circuit or tank probe circuit closes the control will auto matically return to step 2 and repeat the entire operating cycle During this idle state if the control detects an im proper 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 illu minate indicating the nature of the fault DIA SCAN II DISPLAY BOARD OPERATING PROCEDURES The Display Board provides a user friendly interface to the WHC1502 Ignition Control Board With the Display Board the user can control appliance functions and view the overall oper ating status of the appliance If an error condition occurs the Display Board will scroll a message across the LED display indicating the error code Under normal operating conditions the four digit LED display on the Display Board will continuously illustrate the water temperature sensed at temperature probe 1 Outlet The push buttons on the Display Board allow the user to program and view the desired water temperature set point The Display Board is connected to the Ignition 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 WHC1502 System the Display Board will initially run through a self diagnostic test and then display the Outlet temperature To disp
30. 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 cir culate time 45 90 180 On 5 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 6 Thedisplay will automatically resort to illustrating the outlet tem perature Display Current Mode In this mode the Display Board will illustrate the current functional step in the appliance operational sequence For example if the appliance is performing Ignitor Warm up the display will illustrate IGnt To enter into this mode perform the following steps 1 Pressthe SELECT push button on the display board until the LED display reads OPt Options 2 Toenterinto the options mode press the ENTER RESET push button 3 The display will illustrate Circ Press the SELECT push but ton until the display illustrates StEP Enter this mode by press ing the ENTER RESET push button 4 display will illustrate the current appliance operating step 5 The display will automatically resort to illustrating the outlet tem perature To keep the display in the Display Step Mode press ENTER RESET twice in step 3 Display Message Appliance Mode IdLe Idle state NoSn Wait for No Sensor Inputs CrSn Wait for Circulate Sense Circ Circulate Pump is ON PrSn Wait for Blower P
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