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A.O. Smith 1000 Water Heater User Manual

1. 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 Set Point differential for a given stage is being viewed or adjusted See Figure 16 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 included with the boiler The red stage LEDs indicate on which stage a given fault has occurred See Figure 16 Blocked Flue Blockage in Flue Probe Fail One of the controlling Probes has failed Insufficient Air Not enough Air to Close Switch Circulate Fail Flow Switch Not Closed Gas Valve Fail Relay for Gas Valve in Incorrect State High Limit High Limit has been Exceeded Flame Fail No Flame Sensed upon Ignition Igniter Fail Igniter did not reach Minimum Amperage Low Gas Fail Gas Pressure too low to Close Switch 27 DISPLAY SCREEN FRONT PANEL DISPLAY BLOCKED FLUE TEMP PROBE FAIL INSUFFICIENT AIR CIRCULATION FAIL GAS VALVE FAIL HIGH LIMIT RED FAULT LIGHTS FLAME FAIL IGNITER FAIL LOW GAS FAIL HIGH GAS FAIL LWCO FAIL POWER VENT FAIL SELECT O ENTER RESET GENESIS II Figur
2. SUPPLY t TANK TEMP ee CONTROL 4 T CHECK a A 4 VALVE D B i Co RETURN LINE FROM RECIRCULATING DRAIN MOUNTED LOOP IF USED CIRCULATING PUMP 2 Qa da SAFETY FLOW SWITCH MINIMUM T amp P RELIEF MODELS PIPE SIZE VALVE Soe CIRCULATING RETURN INCHES lt LINE CONNECTIONS R2 aE GW 1000 0 TEMPERED WATER LOOP IF USED TER CONNECT TO POINT 2500 gt STORED TEMPERATURE WATER LOOP FACTORY PUMP SIZING 4 IF USED CONNECT TO ANY OPENING BASED ON 50 EQUIVALENT ry NEAR BOTTOM OF TANK FEET 15 2 m OF PIPE BALL VALVE Figure 11 Single boiler with horizontal tank Encase field supplied wires JUNCTION 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 24 VAC junction box see figure 20 This conduit and wiring should be separate from any other conduit wiring to guard against EMI electromagnetic interference Figure 12 Tank probe installation BOX PIGTAILS 18 REMOTE SENSOR WIRES YELLOW CONTROL BOARD ONE GENESIS MODEL GW HOT WATER SUPPLY BOILER WITH VERTICAL TANK PRESSURE RELIEF VALVE RATING SHOULD NOT EXCEED PRESSURE CAPACITY OF ANY COMPONENT IN THE SYSTEM PIPING SHOULD CONFORM TO LOCAL CODES BALL VALVES ARE SHOWN FOR SERVICING BOILER HOWEVER LOCAL CODES SHALL GOVERN THEIR USAGE
3. 12 MIN 30 5 cm ABOVE ANTICIPATED SNOW LEVEL VENT PIPE EXHAUST VENT BOILER UNIT BOILER UNIT Figure 7 TABLE 9 DIRECT VENT VERTICAL EXHAUST CONFIGURATIONS APPLIANCE CERTIFIED EXHAUSTVENT MAXIMUM AIRINTAKE AIR INLET MAXIMUM MODEL CATEGORY EXHAUST VENT SIZE INCHES EXHAUSTVENT MATERIAL SIZE 1 AIRINTAKE MATERIAL LENGTH FEET LENGTH FEET TYPEBOR 10 35 EL 8 35 EQUIVALENT 25 4 cm 10 7 m CPVC 20 3 cm 10 7 m EQUIVALENT PVC ABS CR 1500 30 5 cm 10 7 m CPVC 25 4 cm 10 7 m TYPE BOR y GAL STEEL n EQUIVALENT 14 20 PVC ABS OR 10 9 35 6 6 1 CPVC 25 4 cm 6 1 0 0 3 2 meson 2 EQUIVALENT 35 6 cm 6 1 m CPVC 30 5 cm 6 1 m GAL STEEL Lay EM 16 20 PVC ABS OR 12 2 QU 40 6 cm 6 1 m CPVC 30 5 cm 6 1 m Connection for the appliance exhaust vent to the stack must be as direct as possible Maximum and minimum venting length for Category appliances shall be determined per the latest edition of the National Fuel Code U S CAN CSA B149 1 and 2 Installation Code Canada The vent should be installed so as to prevent the accumulation of condensate and where necessary have means provided for drainage of condensate The horizontal breaching of a vent must have an upward slope of not less than 1 4 inch per linear foot 2 cm m from the boiler to the vent terminal The horizontal portion of the ven
4. 19 Table 13 Suggested Pipe Size For Multiple Gas Appliances Natural Maximum Capacity of Pipe in BTU hr and kW for Gas Pressures of 14 in W C 0 5 psi or Less and a Pressure Drop of 0 5 in W C based on 0 60 Specific Gravity Gas w Heating Value of 1 000 BTU s Ft Length of Pipe in Feet Metres 10Ft 20Ft 30Ft 401 50Ft Gort 70Ft 80Ft 90 Ft 100Ft 125Ft 150 Ft 175Ft 200Ft 3 05 6 10 9 14 12 19 15 24 18 29 21 34 24 38 27 43 30 48 38 10 45 72 53 34 60 96 Lt Br r RD D DE E LEN PR HEZA ADEM Ker RI EE HENI EZ SORI ee REZ ZAD ET ZER HES TES ER TR IRO 2 100 000 1 460 000 1 160 000 990 000 FR DD DD DD Dl DB R Nominal w os zo BERE RN RR RR ER kw s mo ar ze LL 185 zra gre re se em as sr kw 322 2255 180 152 1391 1250 100 o2 me esa Table 14 Suggested Pipe Size For Multiple Gas Appliances Propane Gas Maximum Capacity of Pipe in BTU hr and kW for Gas Pressures of 14 in W C 0 5 psi or Less and a Pressure Drop of 0 5 in W C based 1 53 Specific Gravity Gas w Heating Value of 2 500 BTU s Ft Length of Pipe in Feet Metres 10 Ft 20 Ft 30 Ft 40 Ft 50 Ft 60 Ft 70 Ft 80 Ft 90 Ft 100F
5. IMPORTANT SAFETY FLOW SWITCH PROTECTS THE BOILER IN CASE OF WATER SERVICE INTERRUPTION OR CIRCULATOR FAILURE e PIPE TO OPEN DRAIN X FACTORY INSTALLED ON UNIT SUPPLIED WITH UNIT FIELD INSTALLED REAR MOUNTED CIRCULATING PUMP HOT WATER TO FIXTURES TEMP amp PRESSURE RELIEF VALVE SAFETY FLOW SWITCH T STORAGE TANK T amp P RELIEF VALVE PROBE OR OPTIONAL TANK TEMP CONTROL WATER SUPPLY BUILDING RECIRCULATION BYPASS BALL VALVE AA DANGER TEMPERATURE SETTING SHOULD NOT EXCEED SAFE USE TEMPERATURE AT FIXTURES SEE WATER TEMPERATURE CONTROL WARNING ON PAGE 23 IF HIGHER PREHEAT TEM PERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT ADD AN ANTI SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES gt gt DRAIN TWO TEMPERATURE WATER MIXING VALVE APPLICATION HOT WATER OUTLET MINIMUM MODELS PIPE SIZE INCHES GW 1000 THRU 2500 N CHECK VALVE FACTORY PUMP SIZING BASED ON 50 EQUIVALENT FEET INSTALL THERMAL EXPANSION 15 2 m OF PIPE TANK ON COLD WATER SUPPLY LINE IF CHECK VALVE OR PRESSURE REDUCING VALVE IS USED IN SUPPLY MIXING VALVE CIRCULATING RETURN LINE CONNECTIONS TEMPERED WATER LOOP IF USED CONNECT TO POINT R STORED TEMPERATURE WATERLOOP 7 IF USED CONNECT TO ANY OPENING Figure 13 Single boiler with vertical tank NEAR BOTTOM OF TANK
6. 19 968 000 17 004 000 15 132 000 13 728 000 12 636 000 11 700 000 11 232 000 10 452 000 9 360 000 8 580 000 7 800 000 7 176 000 Kw 10508 7 219 5848 4980 4432 4 021 3 701 3427 3200 3061 2741 2513 2 284 2102 20 GAS CONNECTIONS A WARNING THIS BOILER IS NOT INTENDED TO OPERATE AT GAS SUPPLY PRESSURE OTHER THAN SHOWN ON THE RATING PLATE EXPOSURE TO HIGHER GAS SUPPLY PRESSURE MAY CAUSE DAMAGE TO GAS VALVES WHICH CAN RESULT IN FIRE OR EXPLOSION IF OVERPRESSURE HAS OCCURRED SUCH AS THROUGH IMPROPER TESTING OF GAS LINES OR EMERGENCY MALFUNCTION OF THE SUPPLY SYSTEM THE GAS VALVES MUST BE CHECKED FOR SAFE OPERATION MAKE SURE THAT THE OUTSIDE VENTS ON THE SUPPLY REGULATORS AND THE SAFETY VENT VALVES ARE PROTECTED AGAINST BLOCKAGE THESE ARE PARTS OF THE GAS SUPPLY SYSTEM NOT THE BOILER VENT BLOCKAGE MAY OCCUR DURING ICE BUILD UP OR SNOW STORMS WHEN LOCAL CODES REQUIRE A MAIN MANUAL SHUT OFF VALVE OUTSIDE THE BOILER JACKET A SUITABLE MAIN MANUAL SHUT OFF VALVE MUST BE INSTALLED IN A LOCATION COMPLYING WITH THOSE CODES IT IS IMPORTANT TO GUARD AGAINST GAS VALVE FOULING FROM CONTAMINANTS IN THE GAS WAYS SUCH FOULING MAY CAUSE IMPROPER OPERATION FIRE OR EXPLOSION IF COPPER SUPPLY LINES ARE USED THEY MUST BE APPROVED FOR GAS SERVICE BEFORE ATTACHING THE GAS LINE BE SURE THAT ALL GAS PIPE IS CLEAN ON THE INSIDE TO TRAP ANY DIRT OR FOREIGN MATERIAL IN THE GAS SUPPLY LINE A DIRT LEG
7. 2016 1680 1440 1260 1120 1008 916 840 775 o 3309 2647 2206 181 1655 1471 1324 1203 1103 B Ll evr ante cae 3055 2545 2182 1909 1697 1527 1388 1273 175 eP 3130 2601 2355 2098 1984 1712 1570 1449 apr seas 4276 asea 05s 2673 2876 2198 1944 1782 1645 Pow zeon zaono qas Len eeose terez eos resor noro frossd erie GPH 6338 5071 4225 3622 3169 2817 2535 2305 2113 1950 TABLE 4 HEAT EXCHANGER PRESSURE DROP GB Models Flow Head Loss and Temperature Rise 20 Deg F Rise 30 Deg F Rise 40 Deg F Rise Maximum Flow Rate Minimum Flow Rate PD FT PD FT PD FT PD FT Deg F PD FT Deg F MODEL Head Head EE Ka es Ea GB 1000 GB 1300 GB 1500 GB 1850 GB 2100 40 0 Note GW models GB optional are equipped with pumps capable of handling 50 equivalent feet 15 2 m of normal pipe fittings FOREWORD These designs comply with the latest edition of the American National Standards for Gas Fired Low Pressure Steam and Hot Water Boilers ANSI Z21 13 and CGA 4 9 CGA 3 3 latest edition as a low pressure boiler Detailed installation diagrams are found in this manual These diagrams will serve to provide the installer a reference for the materials and methods of piping necessary It is essential that all water gas piping and wiring be installe
8. Also check for leaks For heating boiler installations Make sure that the boiler and system have been purged of air and checked for leaks Also be sure to check the gas piping for leaks before beginning the initial firing of the boiler FILLING AND PURGING FOR HEATING BOILER INSTALLATION 1 Fast fill system through bypass until pressure approaches desired system pressure Close bypass valve and permit pressure to be established by the pressure reducing valve 2 Vent all high points in system to purge system of air Provisions should be made to permit manual venting of radiators or convectors FILLING FOR HOT WATER SUPPLY BOILER INSTALLATION 1 Close the systems drain valve by turning handle clockwise Open a nearby hot water faucet to permit the air in the system to escape Fully open the cold water inlet pipe valve allowing the heater and piping to be filled Close the hot water faucet as water starts to flow The heater is ready to be operated PURGING OF GAS LINE Gas line purging is required with new piping or systems in which air has entered CAUTION PURGING SHOULD BE PERFORMED BY PERSONS EXPERIENCED IN THIS OF GAS SERVICE TO AVOID RISK OF FIRE OR EXPLOSION PURGE DISCHARGE MUST NOT ENTER CONFINED AREAS OR SPACES WHERE IGNITION CAN OCCUR THE AREA MUST BE WELL VENTILATED AND ALL SOURCES OF IGNITION MUST BE DEACTIVATED OR REMOVED BEFORE PLACING THE BOILER IN OPERATION CHECK FOR GAS LEAKAGE USE
9. appliance be checked every 6 months for dust condensate leakage deterioration and carbon deposits A WARNING DO NOT USE A NYLON BRUSH OR OTHER STATIC CREATING MATERIAL TO CLEAN DUST AND CARBON DEPOSITS FROM HEATING SURFACES AND VENT SUCH DEPOSITS ARE FLAMMABLE AND MAY BE IGNITED BY STATIC ELECTRICITY USE AMETALBRUSH TO MINIMIZE THE DANGER OF EXPLOSION Qualified serviceman should follow this procedure when the boiler s intake and exhaust piping need cleaning 1 Turn off the electrical power and manual gas shut off e Allow boiler parts to cool before disassembly 2 Remove the vent pipe e Check parts and chimney for obstructions and clean as necessary 3 Remove burners from boiler and other metal parts as required to clean as necessary e Refer to parts list supplied with this manual for disassembly aid 4 Clean and reinstall the parts removed in steps 2 and 3 e Be sure the vent pipe has a minimum upward pitch of 1 4 per foot 2 cm m of length and is sealed as necessary 5 Restore electrical power and gas supply to boiler e Check for gas leaks and proper boiler and vent operation HEAT EXCHANGER PREVENTIVE MAINTENANCE In most water supply systems some solids exist As the water is heated these tend to drop out depositing as scale or lime This scale must be removed before the heat exchanger tubes become blocked AcauTION LIME ACCUMULATION CAN REDUCE THE LIFE OF THE EQUIPMENT REDUCE EFFICIENCY AND WASTE FUEL BOILER
10. A SOAP AND WATER SOLUTION OR OTHER MATERIALACCEPTABLE FOR THE PURPOSE OF LOCATING GAS LEAKS DO NOT USE MATCHES CANDLES FLAME OR OTHER SOURCES OF IGNITION FOR THIS PURPOSE A WARNING THE GAS VALVE MUST HAVE BEEN IN THE OFF POSITION FOR AT LEAST 5 MINUTES This waiting period is an important safety step Its purpose is to permit gas that may have accumulated in the combustion chamber to clear IF YOU DETECT GAS ODOR AT THE END OF THIS PERIOD DO NOT PROCEED WITH LIGHTING RECOGNIZE THAT GAS EVEN IF IT SEEMS WEAK MAY INDICATE PRESENCE OF ACCUMULATED GAS SOMEPLACE IN THE AREA WITH RISK OF FIRE OR EXPLOSION SEE THE FRONT PAGE FOR STEPS TO BE TAKEN INLET GAS PRESSURE The inlet gas pressure is measured by removing the low gas pressure switch located on the main gas manifold which is upstream of the unit s combination gas valves The maximum value specified in the table must not be exceeded The minimum values shown in table 17 must be maintained under both load and no load conditions static and dynamic The combination gas valves supplied with the boiler are for low pressure service If upstream pressure exceeds 14 0 W C an intermediate gas pressure regulator of the lockup type must be installed TABLE 17 Nat Gas Prop Gas Max Inlet Pressure Inches W C Min Inlet Pressure Inches 6 0 11 0 MANIFOLD PRESSURE The manifold gas pressure is measured at the pressure tap on the downstream side of the combinatio
11. ALTITUDE UP TO 4 500 FEET ONLY CONSULT THE FACTORY FOR HIGHER ALTITUDES Some utility companies derate their gas for altitude You should contact your gas supplier for any specific changes which may be required in your area Call the local gas utility to verify BTU content of the gas supplied Ratings specified by manufacturers for most boilers apply for elevations up to 4 500 feet 1350 m For elevations above 4 500 feet 1350 ratings must be reduced by a rate of 4 for each 1 000 feet 300 above sea level Example A Genesis boiler is rated at 1 300 000 Btu hr input at sea level At an altitude of 5 000 1500m the prejet orifices will decrease the input rate by 20 4 x 5 to a new rating of 1 040 000 Btu hr 80 x 1 300 000 Btu hr The input reduction is achieved by the prejet orifices through self regulation FEATURES CONTROLS MULTI STAGE FIRING AND CONTROL SYSTEM ALL MODELS The control system consists of three basic components 1 Central Control Board 2 Ignition Control Board and 3 Display Board The Central Control Board and Ignition Control Boards are located in the control box and can be accessed through panels on the left side and top of the unit The Display Board is attached to the front jacket panel The control system is a multi stage control capable of managing three or four ignition stages Three stage models include the 1000 1300 and 1500 Four stage models include the 1850 2100 and 2500 Every s
12. CONTRACT OR TORT a Some states or provinces do not allow the exclusion or limitation of the incidental or consequential damage so the above limitations or exclusions may not apply to you b This warranty gives you specific legal rights and you may also have other rights which vary from state to state or province to province Fill in the following for your own reference Keep it Registration is not a condition of warranty The model and serial number are found on the boiler s rating plate Owner Installation Address City and State or Province Postal Zip Code Date Installed Model No Serial No Dealer s Name Dealer s Address Phone No FILL IN WARRANTY AND KEEP FOR FUTURE REFERENCE 37 ProductPreservers REPLACEMENT PARTS ZAN Co SL M rin WATER PRODUCTS COMPANY 5621 W 115TH STREET ALSIP IL 60803 Phone 800 433 2545 Fax 800 433 2515 www hotwater com E Mail parts hotwater com
13. FAILURE DUE TO LIME OR SCALE BUILDUP VOIDS THE WARRANTY 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 TUBE CLEANING PROCEDURE MECHANICAL REMOVAL OF DEPOSITS Establish a regular inspection schedule the frequency depends on the local water conditions and severity of service Do not let the tubes clog up solidly Clean out deposits over 1 16 1 6 mm thickness To service heat exchanger tubes remove return header casting side opposite the water connections Use a U S standard 5 8 deep socket ratchet to remove the nuts exposing the tube ends Inspect to ensure tubes are free of scale and deposits If scaled remove deposits
14. 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 NEIGHBOR S PHONE FOLLOW THE GAS SUPPLIER S INSTRUCTIONS IF YOU CANNOT REACH YOUR GAS SUPPLIER CALL THE FIRE DEPARTMENT ROBERTSHAW FIGURE TOP KNOB FIGURE 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 WHICH HAS BEEN UNDER WATER DO NOT OPERATE APPLIANCE UNLESS UNIT IS FILLED WITH WATER AND WATER LINES ARE FULLY OPEN WHITE RODGERS Ern FIGURE A FIGURE B la POSITION POSITION A Ge OPERATING INSTRUCTIONS 1 STOP READ THE SAFETY INFORMATION THE NEXT STEP ABOVE ON THIS LABEL SET THE SYSTEM CONTROLLER TO THE LOWEST SETTING TURN OFF ALL ELECTRIC POWER TO APPLIANCE THIS APPLIANCE IS EQUIPPED WITH AN IGNITION DEVICE WHICH AUTOMATICALLY LIGHTS THE BURNER DO NOT TRY TO LIGHT THE BURNER BY HAND REMOVE CONTROL ACCESS PANEL REFER TO DIAGRAMS ABOVE TURN TOP KNOB OF GAS CONTROL CLOCK
15. SOMETIMES CALLED DRIP LEG MUST BE INCORPORATED IN THE PIPING THE DIRT LEG MUST BE READILY ACCESSIBLE AND NOT SUBJECT TO FREEZING CONDITIONS INSTALL IN ACCORDANCE WITH RECOM MENDATIONS OF SERVING GAS SUPPLIERS REFER TO NATIONAL FUEL GAS CODE ANSI 2223 1 OR CAN CSA B149 1 AND 2 AND LATEST ADDENDA Gas Pipe sizing may be larger than heater connections on installations where a significant run of piping is required To prevent damage care must be taken not to apply too much torque when attaching gas supply pipe to gas inlet Fittings and unions in the gas line must be metal to metal type Apply joint compounds pipe dope sparingly and only to the male threads of pipe joints Do not apply compound to the first two threads Use compounds resistant to the action of liquefied petroleum gases THE BOILER MUST BE ISOLATED FROM THE GAS SUPPLY PIPING SYSTEM BY CLOSING ITS MAIN MANUAL GAS SHUT OFF VALVE DURING ANY PRESSURE TESTING OF THE GAS SUPPLY PIPING SYSTEM AT TEST PRESSURES EQUAL TO OR MORE THAN 1 2 PSIG 1 CORRECT GAS Make sure gas on which the boiler will operate is the same as that specified on the rating plate Do not install the boiler if equipped with a different type of gas Consult your gas supplier 2A SIZING GAS SUPPLY LINE For single boiler installations See table 15 2B SIZING GAS SUPPLY LINE For multiple installations of two or more boilers See tables 13 Natural Gas and 14 Propane Gas TABLE 1
16. SYSTEMS GB models or GW models ordered without circulator the circulator is NOT provided and must be field installed LOW WATER CUTOFF Not Supplied If low water protection is required by the authorities having jurisdiction a low water cutoff switch should be installed next to the boiler in the outlet water line as shown in HYDRONIC INSTALLATION section The switch should receive periodic every six months inspection to assure proper operation A low water cutoff device of the float type should be flushed every six months DRAIN VALVE Not Supplied Additional drain valves must be obtained and installed on each boiler and tank for draining purposes SAFETY RELIEF VALVES Your local code authority may have other specific relief valve requirements not covered below A WARNING THE PURPOSE OF A SAFETY RELIEF VALVE IS TO AVOID EXCESSIVE PRESSURE WHICH MAY CAUSE TANK EXPLOSION SYSTEM OR BOILER DAMAGE TO AVOID WATER DAMAGE A DRAIN LINE MUST BE CONNECTED TOASAFETY RELIEF VALVE TO DIRECT DISCHARGE TOASAFE LOCATION ADRAIN LINE MUST NOT BE REDUCED FROM THE SIZE OF THE VALVE OUTLET AND IT MUST NOT CONTAIN ANY VALVES BETWEEN THE BOILERAND THE RELIEF VALVE OR THE RELIEF VALVE AND THE DRAIN EXIT IN ADDITION THERE SHOULD NOT BE ANY RESTRICTIONS IN A DRAIN LINE NOR SHOULD IT BE ROUTED THROUGH AREAS WHERE FREEZING CONDITIONS MIGHT OCCUR DO NOT THREAD OR CAP THE DRAIN LINE EXIT RESTRICTING OR BLOCKING A DRAIN LINE WILL DEFEAT THE PUR
17. 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 To reset the cycle count to zero press the ADJUST push button 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 original cycle count will continue to increment on each gas valve operation 6 display will automatically return to illustrating the controlling probe temperature after five 5 seconds a Appliance Operating Sequence 1 When power is applied to the control system the Display Board will initially run through a self diagnostic routine and then go into its operating mode displaying the temperature sensed at the Inlet probe 2 Ifthe Central Control Board determines the actual water temperature at the controlling temperature probe is below the programmed temperature set point minus the switching differential and the thermostat circuit or tank probe circuit is closed a call for heat is activated 3 control then performs selected system diagnostic checks This includes confirming the proper state of the ECO High Limit device flow switch and pressure switches Note Correct water flow is vital to the operation of the boiler See table 4 in the Installation manual for requirements on flow head loss and heat exchanger pressure drop 4 Ifall checks are succes
18. blower The boiler will then begin additional trials for ignition On stages without an associated blower a five second delay will occur before the gas valves are opened for additional trials for ignition Note Stages on which no blower or igniter is present will bypass the blower and igniter proving periods The gas valves will open five seconds after a call for heat is initiated on the stage 10 All stages will remain running until the set point for a given stage is satisfied If all stages are initiated stage four will 30 drop out first followed by stages three two and one To achieve maximum efficiency stages will reignite if the system water temperature drops below the stage Set Point minus the Set Point Differential Note Once a stage is satisfied the blower associated with that stage will allow a 25 second postpurge before it deactivates 11 Once all of the stages have been satisfied the pump will run for the programmed post circulate cycle factory default 45 seconds See Procedure for Setting Pump Delay on page 30 of the manual The control now enters the idle state This is indicated on the display by the Standby LED The control will continue to monitor temperature and the state of other system devices If the water temperature at the designated system controller drops below the set point value minus the switching differential and the thermostat circuit or tank probe circuit closes the control will return to st
19. drop and temperature rise Figure 10 shows a typical installation of the boiler A system with several flow controlled zones or with a 3 way mixing valve system could present a flow rate to the boiler of less than required for a maximum of 50 F 28 C temperature rise Design system with compensating bypasses to the boiler A system bypass should be installed as shown in figure 10 to prevent boiler circulation starvation when the system zones call for reduced flow This bypass may also be used with multiple boilers manifolded for reverse return flow The system bypass would be installed from boiler outlet to suction side of pump The boiler piping system of a hot water heating boiler connected to heating coils located in air handling units where they may be exposed to circulating refrigerated air must be equipped with flow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle Itis highly recommended that the piping be insulated INSTALLATION AS BOILER REPLACEMENT Installation as boiler replacement on an old system with large water volume may result in condensation within the boiler on cold starts This condensing of water vapor in the combustion area can be prevented if a portion of the system water flow is diverted past the boiler to cause an increase in boiler temperature rise BYPASS BALANCING With systems where water temperature can be expected to drop apprecia
20. hot water heating system The pump must be interlocked with the boiler to prevent boiler operation without water circulation See maximum and minimum flow rate information Since most forced circulation systems will be of the closed type install the water supply line as shown on piping diagram figure 10 Severe damage will occur if the boiler is operated without proper water flow circulation Fast filling of large pipe old radiator installations where high pressures are not available requires bypassing of the pressure reducing valve Generally pressure purging is not possible with a well pump system High point air venting is essential For details refer to OPERATION section of this manual on page 22 If the system is of the open type a pressure reducing valve will not be required as the water supply to the system will be controlled by a manually operated valve An overhead surge tank is required A MINIMUM PRESSURE OF 15 PSI 100 kPa MUST BE MAINTAINED ON THE BOILER AT ALL TIMES to avoid potential damage to the boiler that may not be covered by the warranty 15 CONVENTIONAL SPACE HEATING INSTALLATION Modern fin type boilers are exceptionally fast heating units The low water volumes in relation to firing rates require special attention to water flow rates for smooth efficient operation These considerations for the A O Smith copper heat exchanger boilers are covered below Refer to table 4 showing flow rate vs pressure
21. 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 Itis also advisable to make sure Dip Switch F is set to the OFF position which sets the Outlet temperature Set Point to 210 F 99 C See figure 14 Failure to do this will void the warranty If the tank probe is not designated as the controlling probe the staging of the unit will be controlled by the Inlet Probe and will not use the desired tank temperature as its base Once the tank Probe is designated as the controlling probe the Inlet Water Temperature on the display will default to the tank temperature Refer to Connection Diagram figure 20 and figure 12 in order to connect the tank probe to the boiler See section titled PROCEDURES FOR SETTING TANK PROBE TEMPERATURE following the Lighting Instructions for instructions on how to set the temperature EXPANSION TANK If the system is of the closed type install an expansion tank as shown in figures 11 and 13 The sizing of the expansion tank for a closed system is very important and is directly related to the total water volume of the system Refer to ASME or other reliable specifications for sizing
22. 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 16 2 To enter into the options mode press the ENTER RESET push button 3 display will illustrate Crcu Press the SELECT push button until the display illustrates Ler Enter this mode by pressing the ENTER RESET push button 4 display will illustrate the last error detected by the control 5 The display will automatically resort to illustrating the controlling probe temperature after five 5 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 16 2 To enter into the options mode press the ENTER RESET push button 3 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 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
23. post circulate function With the Display Board the user has the capability to choose between a 45 90 or 180 second post circulate time period or turn the pump on continuously This provides flexibility in selecting the post circulate time to meet specific installation requirements and improves the efficiency of the circulating pump operation 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 16 2 To enter into the options mode press the ENTER RESET push button 3 display will illustrate Crcu Enter this mode by pressing the ENTER RESET push button 4 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 selected post circulate time into controller memory 6 The display will automatically return to illustrating the controlling probe temperature after five 5 seconds Last Error Mode In this mode the Display Board will illustrate the last error which caused the unit to lock out When this mode is entered the three digit failure code that was in memory last will be displayed See table 19 for error codes For example if the appliance locked out due to insufficient air
24. probe 1 Press the SELECT push button on the display board until both the Set Pt LED and Outlet Water Temperature LED see Figure 16 are illuminated 2 The LED display will show the current set point temperature Note 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 atthe probe The Inlet Probe is considered a controlling probe and can be used to control the staging of the unit The inlet probe set point is fully adjustable between the factory set minimum value of 80 F 25 C and a user controlled maximum value which will depend on unit s application In GW applications the maximum Inlet Set Point is 190 F 88 C and in GB application it is 220 F 104 C The Inlet probe Set Point can be adjusted between these two maximum values using Dip Switch G on the Central Control Board which is located inside the control box See Figure 14 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 see Figure 16 are illuminated The LED display will show the current set point temperature
25. with a stiff wire brush or mechanical tube cleaner to bare metal Reinstall return header casting Flush system Note Removal of the heat exchanger is not required A CAUTION IF HEAT EXCHANGER MAINTENANCE REQUIRES TUBING REPLACEMENT SPECIAL PROVISIONS SHALL BE TAKEN TO ENSURE THAT THE DAMAGED TUBES ARE CAREFULLY REMOVED REPLACEMENT TUBES MUST BE PROPERLY INSTALLED AND EXPANDED INTO THE ROLLED TUBE TUB OVER ROLLING MISALIGNMENT OF TUBES OR IMPROPER TIGHTENING OF THE ASSEMBLY MAY RESULT IN LEAKS OR DAMAGE TO THE HEAT EXCHANGER CONTACT YOUR SMITH DEALER FOR DETAILED INSTRUCTIONS REPLACEMENT PARTS Replacement parts may be ordered through A O Smith dealers authorized servicers or distributors Refer to the Yellow Pages for where to call or contact in United States the A O Smith Water Products Company 5621 West 115th Street Alsip IL 60803 1 800 433 2545 or in Canada A O Smith Enterprises Lid 768 Erie Street Stratford Ontario Canada N5A 6T3 519 271 5800 When ordering parts be sure to state the quantity part number and description of the item including the complete model and serial number as it appears on the product Refer to the parts lists for more information For Technical Assistance call A O Smith Technical Information Center at 1 800 527 1953 TROUBLESHOOTING Before any extensive troubleshooting ensure that Power 120 VAC is supplied to the appliance System control tank probe ther
26. 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 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 N 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 24 VAC System Controller Optional A 24 VAC thermostat aquastat can be implemented as a system controller on Genesis units The connection for such devices is located in the 24 VAC junction box at the rear of the unit A 24 VAC thermostat aquastat only be used as an On Off switch for the unit The actual controlling of the staging will be through either the inlet or tank probe To use a 24 VAC system controller dip switch E on the CCB must be switched to the on position See Figure 14 Tank Probe Optional In addition to the Inlet and Outlet ECO Probes units can be optionally equipped with a tank Probe The
27. 5 SINGLE UNIT INSTALLATION SUGGESTED PIPE SIZE eruweut 0 50 51 100 101 200 201 300 01 500 21 2 21 2 1 300000 2 1212 2 e a 1 500 000 2 212 1 850 000 2 a 210 3 2 100 000 2 2 312 Use tables 13 or 14 which are taken from ANSI booklet 2223 1 NATIONAL FUEL GAS CODE or CAN CSA B149 1and 2 and latest addenda to size iron pipe or equivalent gas supply line Table 13 is based on a pressure drop of 0 5 inches of water and a specific gravity of 0 60 approximately that of natural gas LP gas has an S G of about 1 53 If the service pressure is five inches water column or less use one pipe size larger than specified in tables 13 15 in order to minimize pressure drop in the line No additional allowance is necessary for an ordinary number of fittings Where it is necessary to use more than the average number of pipe fittings i e elbows tees and valves in gas supply line use a pipe larger than specified to compensate for increased pressure drop TABLE 16 Orifice Size for Natural and Propane LP Gases U S and Canadian Installations Drill size unless otherwise indicated BTUH Burners Natural Holes Propane Holes GB GW 1000 990 000 0 111 4X 0 071 3X GB GW 2500 2 490 000 0 111 4X 0 071 3X WIRING CONNECTIONS ALL ELECTRICAL WORK MUST BE INSTALLED IN ACCORDANCE WITH THE MOST RECENT VERSION OF THE NATIONAL ELECTRICA
28. ADJACENT TO THE BOILER OPEN CONTAINERS OF FLAMMABLE MATERIAL SHOULD NOT BE STORED OR USED IN THE SAME ROOM WITH THE BOILER If the boiler is installed above the level of heating system terminal units a low water cutoff device must be installed in the boiler outlet at the time of installation For installation locations with elevations above 4 500 feet 1350 m consult the factory A WARNING UNDER NO CIRCUMSTANCES SHOULD THE EQUIPMENT ROOM WHERE THE BOILER IS INSTALLED EVER BE UNDER NEGATIVE PRESSURE PARTICULAR CARE MUST BE TAKEN WHEN EXHAUST FANS COMPRESSORS AIR HANDLING EQUIPMENT ETC MAY INTERFERE WITH THE COMBUSTION AND VENTILATION AIR SUPPLIES OF THIS BOILER CHEMICAL VAPOR CORROSION Heat exchanger corrosion and component failure can be caused by the heating and breakdown of airborne chemical vapors Spray can propellants cleaning solvents refrigerator and air conditioning refrigerants swimming pool chemicals calcium and sodium chloride waxes and process chemicals are typical compounds which are corrosive These materials are corrosive at very low concentration levels with little or no odor to reveal their presence Products of this sort should not be stored near the boiler Also air which is brought in contact with the boiler should not contain any of these chemicals If necessary uncontaminated air should be obtained from remote or outside sources Failure to observe this requirement will void the warranty
29. AS VALVE FAILURE CPU FAULT For additional information please refer to the User s Manual supplied with the boiler or contact A O Smith Technical Services 7 a m to 7 p m Central Time at 1 800 527 1953 Our Internet Site is another source of information 24 hours a day http www hotwater com 34 NEW BOILER LIMITED WARRANTY A O Smith Corporation the warrantor extends the following LIMITED WARRANTY to the owner of this hydronic boiler 1 If within TEN years after initial installation of the boiler the heat exchanger shall prove upon examination by the warrantor to be defective in material or workmanship the warrantor at his option will exchange or repair such part or portion This term is reduced to FIVE years if this boiler is used for volume hot water supply purposes other than hydronic space heating a This warranty is extended to the owner for all other parts or portion during the FIRST year following initial installation of this boiler b The warranty on the repair or replacement of the part or portion will be limited to the unexpired term of the original warranty 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
30. Corporation will not be held liable for any personal injury or property damage due to any dislodging of ice 3 The minimum distance for any window gravity air inlet to a building or from gas or electric meter s is 6 feet 1 8 m horizontally 4 feet 1 2 m below and 24 inches 61 0 cm above 4 The minimum distance from inside corner formed by two exterior walls is 6 feet 1 8 m but 10 feet 3 1 m is recommended where possible 5 Maintain a minimum distance of 4 feet 1 2 m from any soffit or eve vent to the exhaust terminal 6 Maintain a minimum distance of 10 feet 3 1 from any forced air inlet to a building Any fresh air or make up air inlet such as a dryer or furnace area is considered to be a forced air inlet 7 Avoid areas where condensate drainage may cause problems such as above planters patios or adjacent to windows where the steam from the flue gases may cause fogging 8 Select the point of wall penetration where the minimum 1 4 per foot 2 cm m of slope up can be maintained 9 The through the wall termination kit is suitable for zero clearance to combustible materials 10 The mid point of the termination eloow must be a minimum of 12 inches 30 5 cm from the exterior wall 10 FT MIN 3 1 12 IM MIN 30 5 EXHAUST TER MIN EXHAUST BA TE RMI NAL 36 IN MIN 91 4 cm 5 FT MIN 1 5 5 1 5 i 12 IN MIN 30 5 c
31. Fi 1 1 4 41 3 cm REAR VIEW E TABLE 1 GAS AND ELECTRICAL CHARACTERISTICS EXHAUST VENT INLET Manifold Pressure Electrical Characteristics Type of Gas Inches W C Volts Hz GW GB 1000 thru 2500 NATURAL 0 87 120 60 ALTERNATE VENT GW GB 1000 thru 2500 PROPANE 2 49 120 60 All Models Maximum Supply Pressure 14 0 In W C 3 49 kPa Minimum Supply Pressure Natural Gas 6 0 In W C 1 22 kPa Minimum Supply Pressure Propane Gas 11 0 In W C 2 74 kPa Minimum Pressures must be maintained under both load and no load static and dynamic conditions 2 3 4 7 0 cm j 7 114 18 4 Figure 1 TABLE 2 ROUGH IN DIMENSIONS a See N TE TEEN a ee TUNEN Pee ee ae TEN Inches inches cm inches cm Inches Inches cm finches Gw GB 1000 14 1 358 122 310 403 1024 316 260 66 0 468 118 9 TT Exhaus Inlet BTU Hr KW BTU Hr KW Vent Diameter Vent Diameter Water Conn Natural Gas Natural Gas Propane Gas Propane Gas Inches cm Inches cm Size 00 990 000 28995 990 000 28995 o 254 e 20 3 2iNPT 2NPr TABLE 3 RECOVERY CAPACITIES Temperature Rise Degrees MODEL BTU Hr kW 22 2 27 7 33 3 38 89 44 4 50 55 5 61 1 66 7 72 29 GW 1000 990 000 290 1 LPH 9526 7620 6350 5443 4763 4234 3810 3462 3175 2930 2520
32. INSTALLATION CLEARANCES Sufficient area should be provided at the front and sides of the unit for proper servicing For ease of service minimum clearances of 24 61 0 cm in the front and 18 46 0 cm on the sides are recommended It is important that the minimum clearances be observed to allow service to the control box and other controls Observing proper clearances will allow service to be performed without movement or removal of the boiler from its installed location Failure to observe minimum clearances may require removal of the boiler in order to service such items as the heat exchanger and burners In a utility room installation the door shall be wide enough to allow the boiler to enter or to permit the replacement of another appliance Two inch 5 1 cm clearance is allowable from combustible construction to hot water pipes Sufficient clearance should be provided at one end of the boiler to permit access to heat exchanger tubes for cleaning Access to control box items such as the Central Control Board Ignition Control Boards and wiring harnesses is provided through a panel on the left side of the unit An 18 46 0 cm minimum clearance is recommended These boilers are approved for installation on noncombustible flooring in an alcove with minimum clearance to combustibles of 3 inches 7 6 cm Right Side and Back 6 inches 15 2 cm Top Front Alcove 12 inches 30 5 cm Left Side and 6 inches 15 2 cm Vent For installa
33. L CODE CANADIAN ELECTRICAL CODE AND MUST CONFORM TO LOCAL REGULATIONS AN ELECTRICAL GROUND IS REQUIRED TO REDUCE RISK OF ELECTRIC SHOCK OR POSSIBLE ELECTROCUTION Make the ground connection to the wire provided in the electrical supply junction box on the boiler Grounding and all wiring connected to this boiler must conform to the local code authority having jurisdiction or in the absence of such requirements with the National Electrical Code ANSI NFPA 70 or CSA C22 2 most recent edition The Central Control Board and Ignition Control Boards that make up the control system are micro processor based which make them vulnerable to voltage and amperage fluctuations in the power supply It is imperative that they be protected by a suitable commercial grade surge protection device IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH TYPE 105 C WIRE OR ITS EQUIVALENT The Genesis Hot Water Supply Boiler must be connected to a single phase line source that is 120 volts 60 Hertz and 30 Amps The system controller other than the factory supplied tank probe e g Honeywell Aquastat must be wired on the low voltage side of the 24VAC rear junction box Refer to the Schematic Diagram Figure 19 and the Connection Diagram Figure 20 for wire connections Fuse Protection The 24 VAC circuitry is protected with a 3 amp auto fuse on the ignition control boards and a 5 amp fuse
34. LIGHT ANY APPLIANCE e DO NOT TOUCH ANY ELECTRIC SWITCH DO NOT USE ANY PHONE IN YOUR BUILDING e IMMEDIATELY CALL YOUR GAS SUPPLIER FROM NEIGHBOR S PHONE FOLLOW THE GAS SUPPLIER S INSTRUCTIONS IF YOU CANNOT REACH YOUR GAS SUPPLIER CALL THE FIRE DEPARTMENT VALVE HANDLE GAS FLOW ae en MAIN MANUAL GAS VALVE FIGURE A ic POSITION WARNING 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 TURN THE MAIN MANUAL GAS VALVE HANDLE NEVER USE TOOLS IF THE HANDLE WILL NOT TURN BY HAND DON T TRY TO REPAIR IT CALLA QUALIFIED SERVICE TECHNICIAN FORCE OR ATTEMPTED REPAIR MAY RESULT IN A FIRE OR EXPLOSION D DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN UNDER WATER IMMEDIATELY CALL A QUALIFIED SERVICE TECHNICIAN TO INSPECT THE APPLIANCE AND TO REPLACE ANY PART OF THE CONTROL SYSTEM AND ANY GAS CONTROL WHICH HAS BEEN UNDER WATER E DO NOT OPERATE APPLIANCE UNLESS UNIT IS FILLED WITH WATER AND WATER LINES ARE FULLY OPEN FIGURE GAS FLOW OFF POSITION OPERATING INSTRUCTIONS STOP READ THE SAFETY INFORMATION ABOVE ON 1 2 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
35. LLY 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 17 Normal Flame Characteristics 31 NOTE Cleaning of main burners Shut off all gas and electricity to unit 1 Remove main burners from unit 2 Check that burner venturi and ports are free of foreign matter 3 Clean burners with bristle brush and or vacuum cleaner DO NOT distort burner ports Reinstall burners in unit Ensure that all the screws on the burner flange are tightened securely so that the gasket will provide a good seal Also ensure that each orifice is centered with the venturi opening of every burner The washer of the orifice must be inserted a minimum of 1 4 into the burner tube This is critical for proper operation See Figure 18 Also check for good flow of combustion and ventilating air to the unit This is a powered burner and the flame is not supposed to be on the burner The flame should be just above the burner deck approximately 1 8 and blue in color see Figure 17 Visually check flame characteristics through the view port located under the left hand header on the boiler Figure 17 shows the normal flame condition Also refer to the flame label on the unit adjacent to the view port BURNER TUBE ORIFICE WASHER ORIFICE BRACKET Figure 18 Orifice Insertion After placing the boiler in operation check the ig
36. LVE 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 TO A SAFE 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 COMBUSTION AIR FILTER If the combustion air supply to the boiler contains dust dirt drywall dust etc a filter must be installed Air filter is not supplied with the boiler as shipped from the factory The installer must provide a filtering system in the air inlet to the boiler if dust dirt or construction dirt can be pulled into the boiler through the inlet air piping BLOWER COMPARTMENT The blower compartment should be cleaned annually to remove any dirt and lint that may have accumulated in the compartment or on the blower and motor Buildups of dirt and lint on the blower and motor can create excessive loads on the motor resulting in higher that normal operating temperatures and possible shortened service life VENTING MAINTENANCE It is recommended that the intake and exhaust piping of the
37. MPERATURE MAX SET POINT TEMPERATURE EITHER F OR C FOR DISPLAYED TEMPERATURE 3 STAGE 3 TRIALS NOIRI GAS VALVE INLET NO EXTERNAL THERMOSTAT OUTLET 210 F 190 F DEGREES EXTERNAL THERMOSTAT OUTLET 240 F 220 F DEGREES Figure 14 Central Control Board s Dip Switch Configuration and Options 26 IGNITION CONTROL BOARD IGNITER amp COMBUSTION BLOWER OPTIONS TABLE J26 J26 J26 J26 J27 J27 J27 J27 1 1 il n J27 DETAIL NO JUMPERS J26 JUMPER ONLY J27 JUMPER ONLY BOTH J26 amp J27 JUMPERS IGNITER CONNECTED BLOWER CONNECTED IGNITER CONNECTED NO BLOWER CONNECTED BLOWER CONNECTED NO IGNITER CONNECTED NO IGNITER CONNECTED NO BLOWER CONNECTED CN15 e EE De FB13 2 f CN16 FB8 lo INTERCOMMUNICATIONS CABLE Re no 24 CNS Red LED Indicating Fuse Failure 5 Green Polarity LED DETAIIL A Figure 15 Ignition Control Board Jumper Settings switch D on the Central Control Board is placed in the ON position it will show the temperature at the tank probe See Figure 14 The push buttons on the Display Board allow the user to program and view several system parameters described in the following text The Display Board is conn
38. N VENTING THE GENESIS BOILER THROUGH AN OVERSIZED CHIMNEY INCLUDING MASONRY CHIMNEYS ADDITIONAL CARE MUST BE EXERCISED TO ASSURE PROPER DRAFT FOR PROPER OPERATION A MINIMUM DRAFT 0 02 W C AND A MAXIMUM DRAFT OF 0 04 W C MUST BE MAINTAINED IN INSTANCES OF EXCESSIVE DRAFT A BAROMETRIC DAMPER MAY BE REQUIRED TO ASSIST IN MAINTAINING THE PROPER DRAFT DRAFT SHOULD BE MEASURED 2 FEET 0 6 M ABOVE THE BOILER VENT COLLAR WARNING THE INSTRUCTIONS IN THIS SECTION ON VENTING THE BOILER MUST BE FOLLOWED TO AVOID CHOKED COMBUSTION OR RECIRCULATION OF FLUE GASES SUCH CONDITIONS CAUSE SOOTING OR RISKS OF FIRE AND ASPHYXIATION CONNECTING BOILER TO A COMMON VENT Do not connect the boiler to a common vent or chimney with solid fuel burning equipment This practice is prohibited by most local building codes as is the practice of venting gas fired equipment to the duct work of ventilation systems Where a separate vent connection is not available and the vent pipe from the boiler must be connected to a common vent with an oil burning furnace the vent pipe should enter the common vent or chimney at a point ABOVE the flue pipe from the oil furnace UL ULC listed double wall type B 1 gas vents through 16 diameter can be installed in heated and unheated areas and can pass through floors ceilings partitions walls and roofs provided the required clearance is observed At the time of removal of an existing boiler the following st
39. ONE GENESIS MODEL GW WATER SUPPLY BOILER WITH HORIZONTAL TANK INSTALL THERMAL EXPANSION TANK ON COLD WATER SUPPLY LINE IF CHECK VALVE OR PRESSURE REDUCING VALVE IS USED IN SUPPLY A DANGER TEMPERATURE SETTING SHOULD NOT EXCEED SAFE USE TEMPERATURE AT FIXTURES SEE WATER TEMPERATURE CONTROL WARNING ON PAGE 23 IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT ADD AN ANTI SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES A WARNING THE WATER MANIFOLD IS NOT DESIGNED TO SUPPORT THE WEIGHT OF THE WATER PIPING SYSTEM AS ON ALL BOILER INSTALLATIONS SPECIAL CARE MUST BE TAKEN TO ENSURE PROPER SUPPORT TWO TEMPERATURE WATER MIXING VALVE APPLICATION HOT WATER OUTLET TEMPERED WATER N CHECK VALVE MIXING VALVE TO TANK INLET PRESSURE RELIEF VALVE RATING SHOULD NOT EXCEED PRESSURE CAPACITY OF ANY COMPONENT IN THE SYSTEM PIPING SHOULD CONFORM TO LOCAL CODES BALL VALVES ARE SHOWN FOR SERVICING BOILER HOWEVER LOCAL CODES SHALL GOVERN THEIR USAGE T TEMPERATURE AND RELIEF VALVE PIPE TO OPEN DRAIN a Les STORAGE TANK IMPORTANT SAFETY FLOW SWITCH PROTECTS THE BOILER IN CASE OF WATER SERVICE INTERRUPTION OR CIRCULATOR FAILURE e PIPE TO OPEN DRAIN X FACTORY INSTALLED ON UNIT SUPPLIED WITH UNIT FIELD INSTALLED 2 THERMOMETER WATER FIXTURES t TANK PROBE a COLD WATER OR OPTIONAL
40. POSE OF THE RELIEF VALVE AND MAY CREATE AN UNSAFE CONDITION INSTALLA DRAIN LINE WITH A DOWNWARD SLOPE SUCH THAT IT NATURALLY DRAINS ITSELF If any safety relief valve is replaced the replacement valve must comply with the latest version of the ASME Boiler and Pressure Vessel Code Section IV HEATING BOILERS Select a relief valve with a discharge rating NOT less than the boiler input and a set pressure NOT exceeding the working pressure of any component in the system The storage tank temperature and pressure relief valve must comply with the applicable construction provisions of the Standard for Relief Valves and Automatic Gas Shut off Devices for Hot Water Supply Systems ANSI 221 22 or CSA 4 4 and latest addendums The valve must be of the automatic reset type and not embody a single use type fusible plug cartridge or linkage FOR HOT WATER HEATING SYSTEMS the boilers are shipped with a 50 psi pressure relief valve This relief valve is factory installed in the water outlet header of the boiler see figure 1 FOR HOT WATER SUPPLY SYSTEMS the boilers are shipped with a 125 psi pressure relief valve This relief valve is factory installed in the water outlet header of the boiler see figure 1 This ASME rated valve has a discharge capacity that exceeds the maximum boiler input rating and a pressure rating that does not exceed the maximum working pressure shown on the boiler rating plate In addition an A G A design certified
41. S A CAUTION LIMIT CONTROLS ARE SAFETY DEVICES AND ARE NOT TO BE USED AS ATHERMOSTAT The GB GW models incorporate an outlet water probe consisting of two limit controls 1 An adjustable automatic reset limit control that can be set to either 210 F 99 C or 240 F 115 C depending on the application 2 A fixed manual reset limit factory set at 250 F 121 C If the manual reset should open due to high temperature the gas valves will close and the unit will go into lockout If lockout occurs manually push the ENTER RESET push button on the display panel to restart the boiler ON OFF SWITCH The ON OFF switch is a single pole single throw rocker switch The switch provides 120VAC from the line source to the boiler COMBUSTION AIR BLOWER Provides air for combustion process The blower settings are adjustable through the use of the air shutter however blowers are set at the factory and should not need adjustment TANK PROBE FOR HOT WATER SUPPLY SYSTEMS GW models A tank probe is supplied with each hot water supply boiler The inlet water temperature will default to the tank temperature on the display when the tank probe is installed Note Tank Probe must be designated as controlling probe using Dip Switch D on Central Control Board before it can be used for GW hot water supply applications Pigtails of field supplied wires should be spliced to pigtails of tank probe and connected to terminal block in th
42. SITIONS 14 SYSTEM INSTALLATION GENERAL If the system is to be filled with water for testing or other purposes during cold weather and before actual operation care must be taken to prevent a down draft entering the boiler or freezing air from contacting the system Failure to do so may cause the water in the system to freeze with resulting damage to the system Damage due to freezing is not covered by the warranty Good practice requires that all piping etc be properly supported The boilers described in this manual may be used for space hydronic heating or for the heating of potable water If the heater is to be used for hydronic space heating follow the instructions on pages 15 17 given for equipment required for installation as in Figure 10 However if units are to be used for heating potable water the information describing specific systems is found on pages 17 19 See figures 11 and 13 Installations must comply with all local codes HYDRONIC INSTALLATION The following is a brief description of the equipment required for installations noted in this manual All installations must comply with local codes see figure 10 Table 12 INSTALLATION ITEMS PAIR OF SHORT PIPE NIPPLES PAIR OF BOILER LOOP TEES AND BALL VALVE BETWEEN SYSTEM SUPPLY _ RETURN ONE SET PER EACH BOILER SYSTEM SUPPLY TEMPERATURE THERMOMETER DRAIN or BLOW DOWN VALVE WATER SUPPLY LINE These boilers can be used ONLY in a forced circulation
43. 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 STOP FOLLOW B IN THE SAFETY INFORMATION ABOVE ON THIS LABEL IF YOU DON T SMELL GAS GO TO THE NEXT STEP TURN MAIN MANUAL GAS VALVE TO ON POSITION FIGURE A THE VALVE IS ON WHEN THE HANDLE IS PARALLEL TO THE GAS FLOW DIRECTION TURN POWER SWITCH TO ON POSITION SET THE SYSTEM CONTROLLER TO DESIRED SETTING IF THE APPLIANCE WILL NOT OPERATE FOLLOW THE INSTRUCTIONS TO TURN OFF GAS TO THE APPLIANCE AND CALL YOUR SERVICE TECHNICIAN OR GAS SUPPLIER WAIT FIVE 5 MINUTES TO CLEAR OUT ANY GAS THEN SMELL FOR GAS INCLUDING NEAR THE FLOOR IF YOU SMELL GAS TO TURN OFF GAS TO APPLIANCE 1 SET THE SYSTEM CONTROLLER TO THE LOWEST SETTING 2 TURN POWER SWITCH ON APPLIANCE TO OFF POSITION 3 TURN MAIN MANUAL GAS VALVE TO OFF POSITION FIGURE B THE VALVE IS OFF WHEN THE HANDLE IS PERPENDICULAR TO THE GAS FLOW DIRECTION 25 CONTROL SYSTEM DESCRIPTION OF MULTI STAGE FIRING SYSTEM The Central Control Board CCB is responsible for staging the Ignition Control Boards ICB and monitoring safety limit devices control of circulation pump power vent alarm output and IRI gas valves only on IRI models The thermostat also resides on the CCB with inputs available for in
44. WISE TO OFF POSITION FIG A WAIT FIVE 5 MINUTES TO CLEAR OUT ANY GAS THEN SMELL FOR GAS INCLUDING NEAR THE FLOOR IF YOU SMELL GAS STOP FOLLOW B IN THE SAFETY INFORMATION ABOVE ON THIS LABEL IF YOU DON T SMELL GAS GO TO THE NEXT STEP 8 TURN TOP KNOB OF GAS CONTROL COUNTER CLOCKWISE NTO ON POSITION FIG 9 REPLACE CONTROL ACCESS PANEL 10 TURN POWER SWITCH TO ON POSITION 11 SET THE SYSTEM CONTROLLER TO DESIRED SETTING 12 IF THE APPLIANCE WILL NOT OPERATE FOLLOW THE INSTRUCTIONS TO TURN OFF GAS TO THE APPLIANCE AND CALL YOUR SERVICE TECHNICIAN OR GAS SUPPLIER TO TURN OFF GAS TO APPLIANCE SET THE SYSTEM CONTROLLER TO THE LOWEST SETTING TURN POWER SWITCH ON APPLIANCE TO OFF POSITION REMOVE ACCESS PANEL TO EXPOSE GAS CONTROL 4 REFERTODIAGRAMS ABOVE TURN TOP KNOB OF GAS CONTROL CLOCKWISE TO OFF POSITION FIG A 5 REPLACE CONTROL ACCESS PANEL 24 Lighting Instructions for the G B W 1000 through 2500 models FOR YOUR SAFETY READ BEFORE OPERATING THIS APPLIANCE DOES NOT HAVE 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 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
45. ZA o rin COPPER BOILERS FOR HYDRONIC HEATING AND HOT WATER SUPPLY Installation e Operation e Maintenance Limited Warranty 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 PLACE THESE INSTRUCTIONS ADJACENT TO BOILER AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE PRINTED IN U S A 2526 0501 Smith Space Saver Gas Boiler Instruction Manual GB GW MODELS 1000 1300 1500 1850 2100 2500 SERIES 200 201 A CAUTION TEXT PRINTED OR OUTLINED IN RED CONTAINS INFORMATION RELATIVE TO YOUR SAFETY PLEASE READ THOROUGHLY BEFORE INSTALLING AND USING THIS APPLIANCE XV for buying this cost efficient high recovery unit from A O Smith Water Products Co You should thoroughly read and understan
46. ability 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 519 271 5800 a 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 LIABLE BY VIRTUE OF THIS WARRANTY OR OTHERWISE FOR DAMAGE TO ANY PERSONS OR PROPERTY WHETHER DIRECT OR INDIRECT AND WHETHER ARISING IN
47. and ASME rated temperature and pressure T amp P relief valve must be installed on each and every water storage tank in the hot water supply system see figures 11 and 13 The amp relief valve should have a temperature rating of 210 F 99 C a pressure rating NOT exceeding the lowest rated working pressure of any system component and a discharge capacity exceeding the total input of the water boilers supplying water to the storage tank Locate the T amp P relief valve a in the top of the tank or b in the side of the tank on a center line within the upper six 6 inches 15 cm of the top of the tank The tapping shall be threaded in accordance with the latest edition of the Standard for Pipe Threads General Purpose inch ANSI ASME B1 20 1 The location of or intended location for the T amp P relief valve shall be readily accessible for servicing or replacement INSTALLATION INSTRUCTIONS REQUIRED ABILITY INSTALLATION OR SERVICE OF THIS BOILER REQUIRES ABILITY EQUIVALENT TO THAT OF A LICENSED TRADESMAN IN THE FIELD INVOLVED PLUMBING AIR SUPPLY VENTING GAS SUPPLY AND ELECTRICAL WORK ARE REQUIRED LOCATION When installing the boiler consideration must be given to proper location Location selected should be as close to the stack or chimney as practical with adequate air supply and as centralized with the piping system as possible This location should also be such that the gas ignition system components are
48. ar foot 2 cm m from the boiler to the vent terminal The horizontal portion of the vent shall be supported to maintain clearances and to prevent physical damage or separation of joints 10 STANDARD VENT HORIZONTAL CATEGORY III FLUE EXHAUST VENTING OPTIONAL FLUE EXHAUST BOILER UNIT VENT CAP 12 MIN 30 5 cm ABOVE INSULATED ANTICIPATED SNOW LEVEL EXHAUST VENTING Figure 6 TABLE 8 STANDARD HORIZONTAL VENTING CATEGORY III APPLIANCE CERTIFIED EXHAUST MAXIMUM CATEGORY VENTING VENTSIZE VENTLENGTH MATERIAL INCHES FEET STAINLESS STEEL 10 25 4 cm STAINLESS n STEEL 14 35 6 cm STAINLESS STEEL 16 40 6 cm WARNING No substitutions of flue pipe or vent cap material are allowed Such substitutions would jeopardize the safety and health of inhabitants STAINLESS STEEL 12 30 5 cm A maximum of two elbows can be used on inlet and outlet vent piping respectively Each elbow is equal to 10 feet 3 m of straight pipe Use only special gas vent pipes listed for use with Category III gas burning heaters such as stainless steel Saf T Vent by Heat Fab Inc available from A O Smith WPC 5621 W 115th Street Alsip IL 60803 Phone 1 800 433 2545 or Fax 1 800 433 2515 Pipe joints must be positively sealed 11 DIRECT VENT VERTICAL CATEGORY 1 10 FT 3 0 OR LESS j 5 MIN 1 5 36 MIN 91 4 cm 36 MIN 91 4 cm
49. areas making its odor difficult to detect at nose level If LP gas is present or even suspected do not attempt to find the cause yourself Leave the building leaving doors open to ventilate then call your gas supplier or service agent Keep area clear until a service call has been made At times you may not be able to smell an LP gas leak One cause is odor fade which is a loss of the chemical odorant that gives LP gas its distinctive smell Another cause can be your physical condition such as having a cold or diminishing sense of smell with age For these reasons the use of a propane gas detector is recommended IF YOU EXPERIENCE AN OUT OF GAS SITUATION DO NOT TRY TO RELIGHT APPLIANCES YOURSELF Call your local service agent Only trained LP professionals should conduct the required safety checks in accordance with industry standards HIGH ALTITUDE INSTALLATION A WARNING INSTALLATIONS ABOVE 4 500 FEET REQUIRE REPLACEMENT OF THE BURNER ORIFICES IN ACCORDANCE WITH THE NATIONAL FUEL GAS CODE ANSI NFPA 54 FAILURE TO REPLACE THE ORIFICES WILL RESULT IN IMPROPER AND INEFFICIENT OPERATION OF THE APPLIANCE PRODUCING CARBON MONOXIDE GAS IN EXCESS OF SAFE LIMITS WHICH COULD RESULT IN SERIOUS PERSONAL INJURY OR DEATH GENESIS BOILERS ARE EQUIPPED WITH SELF REGULATING PREJET ORIFICES WHICH AUTOMATICALLY COMPENSATE FOR HIGHER ELEVATIONS AND ADJUST THE APPLIANCE S INPUT RATE ACCORDINGLY MAKING IT UNNECESSARY TO REPLACE ORIFICES FOR HIGH
50. bly due to long standby periods or heavy draw down a bypass pipe of at least 1 size with a balancing cock should be installed between the boiler inlet and outlet see figure 10 When the system first starts the valve should be slowly opened until the condensing ceases This adjustment remains at a permanent setting to establish required temperature rise across the boiler AIR SEPARATOR An air separator as shown in the piping diagram is reccommended especially for modern commercial hydronic systems VENT VALVES It is recommended that automatic loose key or screwdriver type vent valves be installed at each convector or radiator SYSTEM HEADERS Split systems with individual supply and return lines from the boiler room should normally have this piping connected to supply and return manifold headers near the boiler To achieve good water distribution with minimum pressure drop for several circuits manifolds should be larger than system loops The circuits should be spaced on the header at a minimum of 3 7 6 cm center to center Install a balancing cock in each return line Manifold headers are recommended for split systems with or without zone valves and also those installations with zone circulators If the system is to be split at remote points good practice requires special attention be given to main pipe sizing to allow balancing of water flow COOLING PIPING When the boiler is used in conjunction with a refrigeration sys
51. can be used on inlet and outlet vent piping respectively Each elbow is equal to 10 feet 3 m of straight pipe Use only special gas vent pipes listed for use with Category gas burning heaters such as stainless steel Saf T Vent by Heat Fab Inc Inc available from A O Smith WPC 5621 W 115th Street Alsip IL 60803 Phone 1 800 433 2545 or Fax 1 800 433 2515 Pipe joints must be positively sealed 13 STANDARD VERTICAL VENTING CATEGORY THIS BOILER MAY BE VENTED ACCORDING TO TABLE 7 ALSO SEE FIGURE 5 AT LEAST TYPE B VENTING MUST BE USED WITH THE STANDARD VENTING OPTION thru the roof USING THE NATIONAL FUEL GAS CODE VENT TABLES TYPE B VENT PIPE CANNOT BE USED IF THE BOILER IS VENTED HORIZONTALLY OR AS A DIRECT VENT SEE PAGES 11 THROUGH 13 ALL LOCAL UTILITY STATE PROVINCIAL REGULATIONS ON VENTING MUST BE FOLLOWED VENT SIZING INSTALLATION AND TERMINATION SHALL BE IN ACCORDANCE WITH THE NATIONAL FUEL GAS CODE ANSI 2223 1 OR CAN CSA B149 1 and 2 AND LATEST ADDENDA Vent connections must be made to an adequate stack or chimney and shall be in accordance with the National Fuel Gas Code ANSI 2223 1 CAN CSA B149 1and 2 and latest addenda or applicable provisions of the local building codes Size and install proper size vent pipe Horizontal runs of vent pipe shall be securely supported by adequately placed approximately every 4 feet 1 2 noncombustible hangers suitable for the weight and desi
52. connection for the tank probe is located in the 24 VAC junction box at the rear of the unit The tank Probe can be configured to control the staging of the unit See Tank Probe Installation section on page 17 for additional information Procedure for Setting Tank Probe Temperature If you have a GW hot water supply boiler and have installed the tank probe below are the instructions on how to adjust the water temperature set point 1 Press the SELECT push button on the display board until both the Set Pt LED and Inlet Water Temperature LED see Figure 16 are illuminated 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 Differential 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 prope
53. d as shown on the diagrams You should thoroughly read and understand this manual before installation and or operation of this boiler The factory warranty will be void if the boiler s have been improperly installed or operated In addition to these instructions the boiler s shall be installed in accordance with those installation regulations in force in the local area where the installation is to be made These shall be carefully followed in all cases Authorities having jurisdiction should be consulted before installations are made In the absence of local codes the installation must comply with the latest editions In the United States The National Fuel Gas Code ANSI Z223 1 NFPA 54 and the National Electric Code NFPA 70 In Canada The installation Code CAN CSA B149 1 and 2 latest edition and the Canadian Electric Code CSA C22 2 These are available from the Canadian Standards Association 8501 East Pleasant Valley Road Cleveland OH 44131 USA or Canadian Gas Association Laboratories 55 Scarsdale Road Don Mills Ontario M3B 2R3 Canada GROUNDING INSTRUCTIONS This boiler must be grounded in accordance with the National Electrical Code and or local codes Boiler is polarity sensitive correct wiring is imperative for proper operation This boiler must be connected to a grounded metal permanent wiring system or an equipment grounding conductor must be run with the circuit conductors and connected to the equi
54. d this manual before installation and or operation of this boiler Please pay particular attention to the important safety and operating instructions as well as the WARNINGS and CAUTIONS CONTENTS ROUGH IN DIMENSIONS CAPACITIES FOREWORD FEATURES CONTROLS INSTALLATION INSTRUCTIONS SYSTEM INSTALLATION HYDRONIC INSTALLATION HOT WATER SUPPLY INSTALLATION GAS CONNECTIONS OPERATION LIGHTING AND OPERATING CONTROL SYSTEM PREVENTATIVE MAINTENANCE TROUBLE SHOOTING LIMITED WARRANTY WIRING DIAGRAM SCHEMATIC ZA SATTA WATER PRODUCTS COMPANY A DIVISION OF A O SMITH CORPORATION EL PASO TX MC BEE SC RENTON WA STRATFORD ONTARIO VELDHOVEN THE NETHERLANDS www hotwater com PART NO 211257 000 REV 0 ROUGH IN DIMENSIONS IMPORTANT TOP VIEW Refer to Installation Clearances section of manual page 7 for recommended service clearances prior 71 2 EXHAUST VENT to boiler placement 19 1 cm G L LEFT SIDE OUTLE 1 17 13 3 cm 47 0 CONTROL CONTAINING CCB AND ICB BOARDS GAS INCET r OPTIONAL PUMP INLET STANDARD t GW MODELS 4 FRONT VIEW WATER DIA SCAN DISPLAY INLET STANDARD 47 1 120 0 FE GW MODELS REF ONLY FLOW SWITCH 14 12 36 8 cm L 30 5 8 RELIEF VALVE 77 8 cm Hamnan
55. doors The installation instructions for confined spaces in tightly constructed buildings must be followed to ensure adequate air supply CONFINED SPACE a U S INSTALLATIONS When drawing combustion and dilution air from inside a conventionally constructed building to a confined space such a space shall be provided with two permanent openings ONE WITHIN 12 INCHES OF THE ENCLOSURE TOP AND ONE WITHIN 12 INCHES OF THE ENCLOSURE BOTTOM Each opening shall have a free area of at least one square inch per 1000 Btuh of the total input of all appliances in the enclosure but not less than 100 square inches If the confined space is within a building of tight construction air for combustion ventilation and draft hood dilution must be obtained from outdoors When directly communicating with the outdoors or communicating with the outdoors through vertical ducts two permanent openings located in the above manner shall be provided Each opening shall have a free area of not less than one square inch per 4000 Btuh of the total input of all appliances in the enclosure If horizontal ducts are used each opening shall have a free area of not less than one square inch per 2000 Btuh of the total input of all appliances in the enclosure b CANADIAN INSTALLATIONS Ventilation of the space occupied by the boiler s shall be provided by an opening for ventilation air at the highest practical point communicating with outdoors The total cross sectiona
56. e 16 Display Board High Gas Fail Gas Pressure at Manifold too High LWCO Low water Cutoff activated Not enough water Power Vent Fail Not Enough Air to Close Switch Stage One Failure on Stage One Stage Two Failure on Stage Two Stage Three Failure on Stage Three Stage Four Failure on Stage Four Yellow Parameter Set Lights The five yellow parameter set lights allow the user to view system set points and options In conjunction with the four green stage LEDs the user can monitor and change settings on the various stages See Figure 16 Inlet Temperature shown is Inlet Water Temperature Outlet Temperature shown is Outlet Water Temperature Set Point Indicated probe set point 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 on Central Control Board is Switched to the ON position See Figure 14 Shows set point temperatures for Inlet Tank or Outlet in conjunction with yellow parameter lights See temperature probe section below TEMPERATURE PROBES All units come with two temperature probes connected to the Inlet Outlet header Additionally an optional tank probe thermistor type or 24V thermostat aquastat can be connected to the unit The probes can be categorized as two types controlling probes and safety limit probes Controlling probes can co
57. e 24 volt junction box See figure 12 for the tank probe installation Follow the instructions for the operation and temperature setting procedures for the tank probe see page 29 FOR HOT WATER HEATING SYSTEMS GB models Due to the many various types of systems and operating conditions a tank probe is not supplied with the models A tank probe be used as an option to control loop temperature and unit staging Additionally the Inlet Temperature Probe can be used as the loop thermostat in some heating GB applications These types of controls connect to designated wires in the junction box at the rear of the boiler Do not operate this boiler using the internal high limits only you must use an operating thermostat as mentioned above Note Additional 24V devices or Tank Probe must be identified using Dip Switches on Central Control Board before they are recognized as a part of the heating system See table 5 and refer to Multi Stage Firing and Control System on previous page for more information about dip switch settings CIRCULATING PUMP The pump flow rate should not exceed the maximum recommended flow rate see table 4 FOR HOT WATER SUPPLY SYSTEMS GW models ordered with the circulator as an integral part of the boiler the pump has been lubricated at the factory and future lubrication should be in accordance with the motor manufacturer s instructions provided as supplement to this manual FOR HOT WATER HEATING
58. e more effective when the boilers are sequenced in and out of operation by some form of main water temperature controller With one or two boilers individual control settings at progressive temperature may be used For more than two boilers electronic sequencing controlling is recommended Individual controls or the separate stages of a step controller should fire a boiler and also start the boiler loop circulator whenever that boiler is fired Some large installations may require the firing of more than one boiler per stage The system or primary circulator may or may not be controlled by the boiler sequencer When this pump is operated through the first switch of any type of step controller care should be taken to determine if a motor starter is needed due to insufficient switch capacity If the primary pump is controlled by a manual switch or any other controllers the electric current supply to the boiler group should be through the primary pump controller The fast response of A O Smith boilers eliminates any need to maintain boiler temperature when the system is satisfied Wiring should always prevent firing of boiler s when there is no water flow in the mains Installation diagrams show safety flow switches in the outlet piping from each boiler as good protection against any boiler being fired when the boiler loop circulator is not in operation These safety flow switches will also provide some protection if there is a loss of wa
59. ected 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 16 After 5 seconds the Display Board will automatically revert to displaying the Inlet temperature Press ing 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 Set point Value e Set Appliance Stage Switching Differential Value e Select Appliance Post Circulate Time e Check Appliance Cycle Count e View Last Error Encountered by Control e Control the water temperature in a storage tank IGNITION CONTROL BOARD IDENTIFICATION JUMPERS TABLE STAGE 1 STAGE 2 STAGE 3 STAGE 4 J24 16792 J24 15792 J24 16 52 J24 35 64 84 3 4 3fo_o 4 se 6 5 a 6 sla sle el 8 NO JUMPER JUMPER JUMPER JUMPER INSTALLED PINS TO6 PIN 3T0 4 1 2
60. ed during installation This is doubly important when a replacement unit is installed into an existing system where Stop Leak or other boiler additives have been used All systems should be completely flushed with a grease removing solution to assure trouble free operation Pipe joint compounds soldering paste grease on tubing and pipe all tend to contaminate a system Failure to clean and flush the system can cause solids to form on the inside of the heat exchanger can produce acid concentrations that become corrosive can allow excessive amounts of air or other gases to form which could block circulation foul system accessories and damage circulator seals and impellers It is recommended that after installation the boiler and system when filled should include the proper percentage of cleaning solution related to approximate water volume of the system Fire and circulate for about one hour and then flush clean with fresh water Commercial grease removing solutions are available Before operating the boiler the entire system must be filled with water purged of air and checked for leaks Do not use Stop Leak or other boiler compounds The gas piping must also be leak tested THE WATER HEATER SHOULD BE LOCATED INAN AREA WHERE THE GENERAL PUBLIC DOES NOT HAVE ACCESS TO SET TEMPERATURES HOT WATER SUPPLY BOILER INSTALLATION WATER LINE CONNECTIONS Where excessive heat exchanger condensation exists due to continued low inlet water tem
61. ential 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 Heating Desired System Temperature 185 85 Stage Differentials 5 F 3 C per Stage Note The user must first choose which probe is to control the staging of the unit The controlling probe will be either the inlet or tank probe If the tank probe is used to regulate loop temperature in hydronic applications GB Models make sure it is located on the return side of the closed loop Use Dip Switch D on the Central Control Board to make this selection See Figure 14 Set the stage differentials using the procedure described in the Procedure for Setting Stage Differential section of the document Setting the control as described in the above example 5 F differentials for each stage will give the following stage set points Stage One Off Temperature 185 F 85 C On Temperature 180 F 82 C Stage Two Off Temperature 180 F 82 C On Temperature 175 F 79 C Stage Three Off Temperature 175 F 79 C On Temperature 170 F 77 C Stage Four Off Temperature 170 F 77 C On Temperature 165 F 74 C Procedure for Setting Pump Delay The Coniroller is factory set with a 45 second
62. ep 2 and repeat the entire operating cycle During this idle state if the control detects an improper operating state for external devices such as the ECO switch air pressure switch gas pressure switch etc the appropriate LED s on the Display Board will illuminate indicating the nature of the fault PREVENTATIVE MAINTENANCE These boilers are designed to give many years of efficient and satisfactory service when properly operated and maintained To assure continued good performance the following recommendations are made 12 The area around the unit should be kept clean and free from lint and debris Sweeping the floor around the boiler should be done carefully This will reduce the dust and dirt which may enter the burner and heat exchanger causing improper combustion and sooting MAIN BURNERS Check main burners every three months for proper flame characteristics The main burner should display the following characteristics Provide complete combustion of gas Cause rapid ignition and carry over of flame across entire burner Give reasonably quiet operation during initial ignition operation and extinction Cause no excessive lifting of flame from burner ports see Figure 17 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 LIGHT BLUE REGION DARK BLUE CONES BURNER VISUA
63. eps shall be followed with each appliance remaining connected to the common venting system Perform these steps while the other appliances remaining connected to the common venting system are not in operation a Seal any unused opening in the common venting system 2 Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion or other unsafe condition 3 Isolate the space containing the appliance s remaining connected to the common venting system as much as possible by closing all openings windows doors etc connected to other spaces in the building Turn on any exhaust fans to their maximum setting and close fireplace dampers Note DO NOT operate summer exhaust fan 4 Test fire the appliance s being inspected making sure to follow the manufacturers lighting and operating instructions Appliance s operating controls should be adjusted to provide continuous service 5 Check vent pressure of appliance 24 inches 61 0 cm above boiler vent collar Vent pressure should be maintained between 0 02 W C and 0 04 W C to assure proper operation For appliances with a draft hood check for spillage with mirror smoke or other device five minutes after placing appliance in operation 6 After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above return doors wind
64. given in table 19 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 LED Controller Function Blocked Flue Indicates a blockage or interference at the appliance flue Indicates failure at one of the temperature probes Unit will lock out only if controlling probe fails Indicates air pressure was too low to create a sufficient differential to close the differential pressure 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 Temperature 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 mee
65. gn of the materials employed to prevent sagging and to maintain a minimum upward slope of 1 4 per foot 2 cm m from the boiler to the vent terminals Dampers or other obstructions must not be installed in the vent Be sure that the vent connector does not extend beyond the inside wall of the chimney Table 11 VENT CONNECTION 10 25 4 cm 12 30 5 cm 12 30 5 cm 14 35 6 cm 14 35 6 cm 16 40 6 cm For vent arrangements other than table 7 and for proper boiler operation a barometric damper is required to maintain draft between 0 02 W C and 0 04 W C at 2 feet 0 6 m above the boiler vent collar TRIM INSULATION FROM AROUND FLUE HOLE Figure 9 Switching from Vertical to Horizontal Venting STANDARD HORIZONTAL VENTING CATEGORY Ill Vent sizing installation and termination shall be in accordance with the NATIONAL FUEL GAS CODE ANSI 2223 1 OR CAN CSA B149 1 AND 2 LATEST EDITIONS If applicable all local utility state provincial regulations on venting must be followed See table 8 for venting specifications The exhaust vent pipe must be of a type listed for use with Category III gas burning heaters such as Saf T Vent manufactured by Heat Fab Inc For Category Ill installations It is important that the Installed vent be airtight Please insure that all joints are sealed properly during installation DIRECT VENT VERTICAL AND HORIZONTAL VENTING For direct vent applications this boiler may be ve
66. he control panel to measure the air pressure in the pre mix chamber The negative pressure tap measures the pressure taken at the burner s auxiliary tube Connections can be seen by removing the lower front jacket panel It is important that this panel remain sealed at all times while the boiler is operating This differential pressure switch is normally open and closes when the combustion blower starts BLOCKED FLUE PRESSURE SWITCH The blocked flue pressure switch ensures that the flue gas vent is clear This pressure switch is normally closed and only opens on the fault conditions FLAME SENSOR The flame sensor acts to prove the flame has carried over from the ignitor to the right most burner If no flame is sensed the gas valve s will close automatically If no flame is sensed on three ignition trials the boiler will lock out Upon lockout manually push the ENTER RESET button on the display panel to restart the boiler WATER FLOW SWITCH The Water Flow Switch is installed at the boiler outlet to prevent burner operation in the event of inadequate water flow through the boiler The Water Flow Switch is a single pole normally open switch that will close its contacts when increasing water flow rate is encountered This switch is factory set but may require field adjustment The contacts will open when the flow rate drops below the adjusted setting and the gas valve s will close turning off the gas to the burners LIMIT CONTROL
67. he water temperature be set for the lowest temperature which satisfies the user s hot water needs This will also provide the most energy efficient operation of the boiler and minimize scale formation in the heat exchanger thus prolonging the life of the boiler SETTING THE WATER HEATER TEMPERATURE AT 120 F 49 C WILL REDUCE THE RISK OF SCALDS Some states require settings at specific lower temperatures Table 18 below shows the approximate time to burn relationship for normal adult skin TABLE 18 Risk of Scalds Temperature Time to Produce 2nd amp 3rd Over 170 77 150 F 66 C About 1 1 2 seconds 140 F 60 C Less than 5 seconds 130 F 54 C About 30 seconds 120 F 49 C or less 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 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 LIGHTING SMELL ALL AROUND THE APPLIANCE AREA FOR GAS BE SURE TO SMELL NEXT TO THE FLOOR BECAUSE SOME GAS IS HEAVIER THAN AIR AND WILL SETTLE ON THE FLOOR WHAT TO DO
68. installed and fresh water used for filling and makeup purposes a This warranty shall apply only when the boiler is used 1 at temperatures not exceeding the maximum setting of its operative and or high limit control 2 at water pressure not exceeding the working pressure shown on the boiler 3 when filled with boiler water free to circulate at all times and with the heat exchanger free of damaging scale deposits 4 in a noncorrosive and non contaminated atmosphere 5 in the United States its territories or possessions and Canada 6 at a water velocity flow rate not exceeding or below the Boiler s designed flow rates b Any accident to the boiler any misuse abuse including freezing or alteration of it any operation of it in a modified form will void this warranty 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 merchant
69. l system during lock out Changes made to programmable features are stored in non volatile memory DIA SCAN II DISPLAY BOARD OPERATING PROCEDURES The Display Board provides a user friendly interface to the Central Control Board With the Display Board the user can control appliance functions and view the overall operating status of the appliance If an error condition occurs the Display Board will indicate the nature of the fault by illuminating a red LED The display will further define the fault by illuminating a red LED corresponding to the stage on which the fault has occurred Red and green LEDs are associated with each stage to indicate either a fault or normal operation If the fault continues until the unit locks out the display will show a three digit code in addition to the red LEDs See Table 19 for error code chart Under normal operating conditions the four digit LED display on the Display Board will continuously illustrate the water temperature sensed at the inlet temperature probe If dip INTERCOMMUNICATIONS CABLE 6 PIN CONNECTOR RS 232 MODEM CABLE 8 PINCONNECTOR DISPLAY PANEL BLE ON 4 STAGE 1 TRIAL IRI GAS VALVE TANK SELECTION EITHER 3 OR 4 STAGE SYSTEM EITHER3 OR 1 WHETHER SYSTEM IS IRIOR STANDARD INLET OR TANK AS CONTROLLING PROBE WHETHER EXTERNAL THERMOSTAT IS USED OUTLET MAXIMUM TE
70. l area shall be at least 10 of the area of the combustion air opening but in no case shall the cross sectional area be less than 10 square inches 6500 In addition to the above there shall be permanent air supply opening s having a cross sectional area of not less than 1 square inch per 7 000 BTUH 310 mm KW up to and including 1 000 000 BTUH plus 1 square inch per 14 000 BTU in excess of 1 000 000 BTUH This opening s shall be located at or ducted to a point neither more than 18 46 0 cm nor less than 6 inches 15 2 cm above the floor level Where power vented equipment is used in the same room as the boiler sufficient air openings must be supplied UNDERSIZED OPENINGS MAY RESULT IN INSUFFICIENT AIR FOR COMBUSTION Where an exhaust fan is installed in the same room with a boiler sufficient openings for air must be provided in the walls UNDERSIZED OPENINGS WILL CAUSE AIR TO BE DRAWN INTO THE ROOM THROUGH THE CHIMNEY CAUSING POOR COMBUSTION SOOTING MAY RESULT WITH AN INCREASED RISK OF ASPHYXIATION VENTING This boiler is approved to be vented as a Category Category III horizontal venting or a Direct Vent appliance The Horizontal and Direct Venting options require a special vent kit TABLE 6 DIRECT VENT KITS G W B 1000 G W B 1300 G W B 1500 G W B 2100 Vertical Direct Vent Kit No Model Number 211089 G W B 1000 211089 1 G W B 1300 G W B 1500 G W B 2100 G W B 2500 CAUTION WHE
71. let outlet and tank temperature probes as well as an input for a remote 24 VAC thermostat The CCB has a display interface which connects to the Display Board to show system status and failures The CCB also has a set of DIP switches which allows the user to control several system parameters See Figure 14 Each stage requires an Ignition Control Board ICB which is responsible for controlling a combustion blower hot surface igniter and gas valve Each ICB is capable of monitoring gas valve power gas valve relay flame sense and igniter current The ICB is designed to communicate with the Central Control Board CCB Each ICB consists of identical hardware and software Each stage ICB is made unique through the use of circuit board jumpers which allow the user to control such variables as stage identification and blower igniter usage See Figure 15 for jumper configurations 0000000000000 These jumpers are pre set at the factory and should only be adjusted by a qualified service technician The Display Board allows the end user to monitor water temperature set points differentials options fault indications and error codes Display Board pushbuttons labeled ADJUST SELECT AND ENTER RESET enable the user to adjust set points differentials post circulate time reset the cycle count and reset the contro
72. m Le EXHAUST TER MIN AL 121N MIN 30 5 ABOVE ANTICIPATED SNOW LEVEL STANDARD VENT VERTICAL CATEGORY 1 4 10 3 0 VENT CAP OR LESS 24 61 0 cm MIN VENT PIPE IMPORTANT VENT PRESSURE MUST BE MAINTAINED BOILER UNIT BETWEEN 0 02 W C AND 0 04 W C AT 24 61 0 cm ABOVE BOILER COLLAR 7 a Figure 5 TABLE 7 STANDARD VERTICAL VENTING CATEGORY APPLIANCE CERTIFIED EXHAUST MAXIMUM LENGTH WITHOUT CATEGORY VENTING VENT SIZE BAROMETRIC DAMPER FEET MATERIAL INCHES TYPE BOR 10 25 4 cm 35 Feet 10 7 m without damper 1000 EQUIVALENT 70 Feet 21 3 m max with damper 1300 TYPE BOR 35 Feet 10 7 m without damper 1500 EQUIVALENT 12 30 5 cm 70 Feet 21 3 m max with damper 1850 TYPE BOR 14 35 6 cm 35 Feet 10 7 m without damper 2100 EQUIVALENT 70 Feet 21 3 m max with damper TYPE BOR 16 40 6 cm 35 Feet 10 7 m without damper EQUIVALENT 70 Feet 21 3 m max with damper Extending venting over 70 feet 21 3 m may require special considerations Connection for the appliance exhaust vent to the stack must be as direct as possible Maximum and minimum venting length for Category appliances shall be determined per the latest edition of the National Fuel Code U S and CAN CSA B149 1 and 2 Installation Code Canada The horizontal breaching of a vent must have an upward slope of not less than 1 4 inch per line
73. mostat etc is calling for appliance operation call for heat Other contacts switches are closed low water cutoff flow switch limit controls pressure switches etc Gas supply pressure is within the maximum and minimum operating ranges listed on the appliance rating plate label Appliance is wired according to wiring diagram NOTE Shorting the thermostat wiring to ground in the 24 volt circuit will blow the 3 amp fuse All wire terminals connectors are firmly attached to valves modules switches limit controls etc There has been no damage caused by freezing inoperative pumps etc CAUTION MAKE SURE POWER IS DISCONNECTED FROM MAIN BREAKER BEFORE SERVICING CAUTION LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS WIRING ERRORS CAN CAUSE IMPROPER FUNCTIONING OF UNIT RESULTING IN PROPERTY DAMAGE PERSONAL INJURY OR LOSS OF LIFE TROUBLESHOOTING IGNITION SYSTEM The control system has several features to aid in troubleshooting problems which may occur during operation If a fault occurs the 33 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
74. n gas valve s For natural gas the Manifold Pressure should measure 3 5 W C For propane LP gas the pressure should read 10 W C IMPORTANT UNDER NO CIRCUMSTANCES SHALL THE GAS PRESSURE MEASURED AT THE BURNER MANIFOLD EXCEED THAT STATED ON THE BOILER RATING PLATE OVERFIRING WILL RESULT IN DAMAGE TO THE BOILER AS WELL AS INCREASED RISK OF FIRE SOOTING AND ASPHYXIATION ADJUSTMENTS ON INITIAL STARTUP SOME ADJUSTMENTS ARE NECESSARY 1 CHECK MANIFOLD AND INLET GAS PRESSURES 23 2 CHECK THE INPUT SEE SECTIONS INLET GAS PRESSURE AND SEE NATIONAL FUEL GAS CODE ANSI 223 1 OR CAN CSA B149 1 AND 2 AND LATEST ADDENDA FOR PROCEDURES 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 CHILD OR DISABLED PERSON UNATTENDED IN A BATHTUB OR SHOWER THE WATER HEATER SHOULD BE LOCATED IN AN AREA WHERE THE GENERAL PUBLIC DOES NOT HAVE ACCESS TO SET TEMPERATURES DANGER It is recommended in domestic hot water applications that lower water temperatures be used to avoid the risk of scalding It is further recommended in all cases that t
75. nition 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 4 500 feet 1350 m refer to HIGH ALTITUDE INSTALLATIONS in the installation section THE FLOW OF COMBUSTION AIR TO THE BOILER MUST NOT BE OBSTRUCTED THE BOILER AREA MUST BE KEPT CLEAR AND FREE FROM COMBUSTIBLE MATERIALS GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS Any safety devices including low water cutoffs used in conjunction with this boiler should receive periodic every six months inspection to assure proper operation A low water cutoff device of the float type should be flushed every six months Periodic checks at least twice a year should be made for water and or gas leaks More frequent inspections may be necessary depending on water conditions The boiler mounted gas and electrical controls have been designed to give both dependable service and long life However malfunction can occur as with any piece of equipment It is therefore recommended that all components be checked periodically by a qualified serviceman for proper operation RELIEF VA
76. nted according to tables 9 and 10 For category Ill applications the exhaust vent pipe must be special gas vent pipe listed for use with category IIl gas burning heaters such as Saf T Vent manufactured by Heat Fab Inc This vent system must be 100 sealed with a condensate trap located as close to the boiler as possible When sizing exhaust piping and intake air piping 90 degree elbows are equivalent to 10 feet 3 1 m of straight pipe and 45 degree elbows are equal to 5 feet 1 5 m of straight pipe The intake air piping can be PVC CPVC ABS or any suitable intake air piping that can be sealed Combustion air from outside the building ducted to boiler air inlet Ducted Air Application cannot be used in rooms with negative pressure HORIZONTAL VENT INSTALLATION This boiler can be vented through the rear of the cabinet with the use of the Fluebox and vent adaptor Any of the previous venting configurations can be installed with rear connections To change the unit to rear exhaust 1 The vent collar and cover plates must be removed from the top and rear of the unit 2 Trim the insulation from around the rear flue hole in the jacket and the fluebox Support insulation from inside the fluebox to facilitate cutting Use safety precautions such as gloves Place the gasket and vent adaptor in the horizontal position Place the gasket and flue plate in the vertical position as shown in figure 9 SWAP FLUE COLLAR gt AND PLATE PO
77. ntrol the staging of the boiler Safety limit probes are used as resettable high limit switches The two controlling probes are the inlet probe and the tank probe The function and setting of the probes is further described in the following sections 28 YELLOW PARAMETER SET LIGHTS 5ET PT DIFF STAGE STATUS LIGHTS STANDBY stace1 sSTAGE2 O sTAGE4 JEZE DISPLAY CABLE 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 250 121 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 99 C and GB applications it is 240 F 115 C The Outlet probe Set Point can be adjusted between these two values using Dip Switch F on the Central Control Board inside the control box See Figure 14 To view the current programmed temperature set point for the Out let Temperature
78. on the Central Control Board If the fuse opens a red LED located near the fuse will light see figures 14 and 15 If the red LED is illuminated replace the fuse Repeated failure of the fuse is an indication of possible damage to the ignition control The 120V circuits of each ignition control module is protected with a 10 amp fuse located inside the control box Note Four extra 3 amp fuses and one 5 amp fuse are supplied with the boiler Recommended Replacement fuses 3 Amp Littlefuse automotive fuse PN 257003 5 Amp Bussman Automotive fuse PN ATC5 22 OPERATION IMPORTANT Only qualified personnel shall perform the initial firing of the heater At this time the user should not hesitate to ask the start up technician any questions regarding the operation and maintenance of the unit If you still have questions please contact the factory or your local A O Smith representative Lighting and Operating instructions are included with this manual By using these instructions the user may be able to make minor operational adjustments and save unnecessary service calls However the user should not attempt repairs but should contact a service technician or gas supplier GENERAL Never operate the boiler without first making sure the boiler and system are filled with water in addition For hot water supply installations Make sure a temperature and pressure relief valve is installed at the boiler and if used the storage tank
79. ows exhaust fans fireplace dampers and other gas burning appliances to their previous conditions of use All boiler venting systems shall be installed in accordance with the National Fuel Gas Code ANSI 2223 1 or CAN CSA B149 1 and 2 and latest addendums or applicable provisions of the local building codes CAUTION Direct venting into dead air spaces such as alleys atriums and inside corners can cause recirculation of flue gases Recirculation of flue gases will cause sooting premature failure of the heat exchanger and icing of the combustion air intake during severe cold weather To prevent the recirculation of flue gases maintain as much distance as possible between the combustion air intake and the exhaust vent terminal 4 FT MIN 1 2 m EXHAUST TERMINAL 12 IN MIH 30 5 cm 6 FT MIH 1 8 m MIN 1 2 m Figure 4 Vent Termination Installation Clearances LOCATION REQUIREMENTS INTAKE EXHAUST Intake Exhaust Installation Requirements See figure 4 1 The termination must be 12 inches 30 5 cm above snow or grade level whichever is higher 2 Due to normal formation of water vapor in the combustion process horizontal terminations must not be located over areas of pedestrian or vehicular traffic i e public walkways or over areas where condensate could create a nuisance or hazard This is especially true in colder climates where ice buildup is likely to occur A O Smith
80. peratures below 120 F a bypass balance loop must be installed see figures 11 and 13 HARD WATER CONDITIONS Where hard water conditions exist water softening or the threshold type of water treatment is recommended This will protect the dishwashers coffee urns water heaters water piping and other equipment When water softening or water treatment is not practical a comparatively easy method of periodic lime removal from the unit must be employed WARNING LIME ACCUMULATION CAN REDUCE THE LIFE OF THE EQUIPMENT REDUCE EFFICIENCY AND WASTE FUEL BOILER FAILURE DUE TO LIME OR SCALE BUILDUP VOIDS THE WARRANTY Tank Probe Optional In addition to the Inlet and Outlet ECO Probes units can be optionally equipped with a tank Probe The connection for the tank probe is located in the 24VAC junction box at the rear of the unit The tank Probe can be configured to control the staging of the unit See Tank Probe Installation section below for additional information TANK PROBE INSTALLATION PROCEDURE A tank probe is supplied with each hot water supply boiler GW To connect the tank probe to the boiler remove the cover from the 24 VAC junction box at the rear of the unit Connect the probe wires across terminals 1 amp 2 The wires leading to the terminals will be yellow Check the field connection diagram located on this cover of the junction box to assure proper wiring Once the tank probe has been connected to the boiler it
81. pment grounding terminal or lead on the boiler A WARNING YOUR BOILER IS NOT DESIGNED TO OPERATE WITHA BOILER INLET WATER TEMPERATURE OF LESS THAN 120 F 38 C COLDER INLET WATER TEMPERATURE WILL RESULT IN SIGNIFICANT CONDENSATION DEVELOPING ON THE HEAT EXCHANGER THIS SITUATION CAN CAUSE A CORROSIVE ENVIRONMENT FOR THE HEAT EXCHANGER BURNERS AND VENTING RESULTING IN PREMATURE DAMAGE WHICH COULD RESULT IN SERIOUS PERSONAL INJURY OR DEATH FOR SYSTEMS THAT USE LARGE VOLUMES OF COLD WATER OR SYSTEMS UTILIZING HEAVY WATER DRAWS CONDENSATION CAN BE PREVENTED BY USING ABYPASS LOOP CORRECT GAS Make sure the gas on which the boiler will operate is the same as that specified on the boiler rating plate Do not install the boiler if equipped for a different type of gas consult your gas supplier PRECAUTIONS IF THE UNIT IS EXPOSED TO THE FOLLOWING DO NOT OPERATE UNTIL ALL CORRECTIVE STEPS HAVE BEEN MADE BY A QUALIFIED SERVICEMAN EXPOSURE TO FIRE IF DAMAGED FIRING WITHOUT WATER SOOTING eh IF THE BOILER HAS BEEN EXPOSED TO FLOODING IT MUST BE REPLACED LIQUID PETROLEUM MODELS Boilers for propane or liquefied petroleum gas LPG are different from natural gas models A natural gas boiler will not function safely on LP gas and no attempt should be made to convert a boiler from natural gas to LP gas LP gas must be used with great caution It is highly explosive and heavier than air It collects first in the low
82. protected from water dripping spraying etc during appliance operation and service circulator replacement control replacement etc THE BOILER MUST NOT BE INSTALLED ON CARPETING THE BOILER SHOULD NOT BE LOCATED IN AN AREA WHERE IT WILL BE SUBJECT TO FREEZING THE BOILER SHOULD BE LOCATED NEARA FLOOR DRAIN THE BOILER SHOULD BE LOCATED IN AN AREA WHERE LEAKAGE FROM THE BOILER OR CONNECTIONS WILL NOT RESULT IN DAMAGE TO THE ADJACENT AREA OR TO LOWER FLOORS OF THE STRUCTURE WHEN SUCH LOCATIONS CANNOT BE AVOIDED A SUITABLE DRAIN PAN SHOULD BE INSTALLED UNDER THE BOILER Such pans should be fabricated with sides at least 2 1 2 6 5 cm deep with length and width at least 2 5 1 cm greater than the dimensions of the boiler and must be piped to an adequate drain The pan must not restrict combustion air flow A WARNING THERE IS A RISK IN USING FUEL BURNING APPLIANCES IN ROOMS OR AREAS WHERE GASOLINE OTHER FLAMMABLE LIQUIDS OR ENGINE DRIVEN EQUIPMENT OR VEHICLES ARE STORED OPERATED OR REPAIRED FLAMMABLE VAPORS ARE HEAVY AND TRAVELALONG THE FLOOR AND MAY BE IGNITED BY THE IGNITER OR MAIN BURNER FLAMES CAUSING FIRE OR EXPLOSION SOME LOCAL CODES PERMIT OPERATION OF GAS APPLIANCES IF INSTALLED 18 INCHES 46 0 CM OR MORE ABOVE THE FLOOR THIS MAY REDUCE THE RISK IF LOCATION IN SUCH AN AREA CANNOT BE AVOIDED FLAMMABLE ITEMS PRESSURIZED CONTAINERS OR ANY OTHER POTENTIAL FIRE HAZARDOUS ARTICLES MUST NEVER BE PLACED ON OR
83. r operation and maximize appliance performance each stage has a programmable operating switching differential or hysteresis about the set point This means a call for heat for a particular stage will become active when the water temperature measured at the controlling temperature sensing probe drops to the set point value minus the switching differential value It is necessary to set three set point differential values for three stage units and four for four stage The burner will remain on until the water temperature measured at controlling probe reaches the stage set point value The switching differential value is fully programmable from 0 F to 20 F 0 C to 11 C using the push button s located on the Display Board To change or view the current programmed switching differential 1 Press the SELECT push button on the display board until both the Set Pt Diff and green Stage One LED see Figure 16 are illuminated 2 The LED display will show the current differential for stage one 3 Press and hold the ADJUST push button The displayed value will either increase or decrease To alternate between increasing or decreasing the differential release then press and hold the ADJUST push button 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 deferential into controller memory To view the Set Pt minus the Set Pt differ
84. sfully 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 5 When the pre purge cycle is complete all blowers except stage 1 will drop out Power is applied to the stage 1 ignitor element for the ignitor warm up period 6 The control will verify ignitor current After the verification the gas valve will open allowing gas to enter the burner 7 After an additional 1 second the control will monitor the flame sense probe to confirm a flame is present If a flame is not verified within 4 seconds the gas valve is immediately closed The control will initiate an 15 second inter purge period and return to step 2 unless dip switch B is in the ON position see fig 14 in which case it will proceed to lock out 8 If a flame is confirmed stage two will be activated The blower associated with stage two will start Once the blower has been proven igniter two will begin its warm up period This is true on all units except the 1000 which has only one igniter After the igniter current has been proven stage two will begin a trial for ignition 9 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
85. t 125Ft 150Ft 175Ft 200Ft 3 05 6 10 9 14 12 19 15 24 18 29 21 34 24 38 27 43 30 48 38 10 45 72 53 34 60 96 BTU hr _1 060 800 zq ee eee Tee ee ee ee ee 31 EEE BEEN EEE ER BERE ER EEE EE BER EN BER RR BEEN BERE ER BER BTU hr 2 184 000 1 482 000 1 201 200 1 029 600 kw 60 44 352 302 BERE EE 1172 BTU hr 3 276 000 2 277 600 1 840 800 1 544 400 1 404 000 1 263 600 1 170 000 1 076 400 1014000 kw 959 667 539 j 452 m 370 343 315 207 BTU hr 6 162 000 4 290 000 3 432 000 2 964 000 2 620 800 2 371 200 2 184 000 2 028 000 1 903 200 1 794 000 1 591 200 1 482 000 1 326 000 1 248 000 kw 1 805 1 256 1005 86s 76 69 640 594 557 52 466 434 388 366 21 2 BTU hr 9 828 000 6 786 000 5 491 200 4 680 000 4 134 000 3 744 000 3 510 000 3 198 000 3 042 000 2 886 000 2 574 000 2 340 000 2 137 200 1 999 800 kw 2878 1987 1608 1 371 121 1097 1028 937 801 845 754 68 626 585 3 BTU hr 17 160 000 9 750 000 8 268 000 7 410 000 6 708 000 6 084 000 5 772 000 5 382 000 5 070 000 4 602 000 4 134 000 3 822 000 3 556 800 Nominal BTU hr 35 880 000 251859 648 000
86. t minimum value which allows trial for ignition to continue Inlet gas pressure is not sufficient to close gas pressure switch Manifold gas pressure is 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 Verify proper operation after servicing Table 19 Error Code Chart GENESIS II CONTROL FAULT OPERATION ERROR CODES LOCKOUT COMMUNICATIONS FAULT CCB TOICB 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 BLOCKED FLUE 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 G
87. t shall be supported to maintain clearances and to prevent physical damage or separation of joints 12 DIRECT VENT HORIZONTAL CATEGORY III 12 MIN 30 6 cm ABOVE ANTICIPATED SNOW LEVEL ZAZA A EXHAUST VENT AIR INTAKE VENT FLUE EXHAUST a Si VENT CAP BOILER UNIT 12 MIN 30 6 cm ABOVE ANTICIPATED SNOW LEVEL 12 MIN 30 6 cm ABOVE ANTICIPATED SNOW LEVE Figure 8 TABLE 10 DIRECT VENT HORIZONTAL EXHAUST CONFIGURATIONS APPLIANCE CERTIFIED VENT MAXIMUM AIRINTAKE AIR INLET MAXIMUM MODEL CATEGORY EXHAUST VENT SIZE VENTLENGTH MATERIAL SIZE AIRINTAKE MATERIAL INCHES FEET INCHES LENGTH FEET STAINLESS 10 35 tayina 8 35 SEALED 25 4 cm 10 7 m CPUC 20 3 cm 10 7 m GAL STEEL 1300 STAINLESS 12 35 ABSCR 10 35 1500 SEALED 30 5 cm 10 7 m CPVC 25 4 cm 10 7 m GAL STEEL STAINLESS 14 20 5 10 20 SEALED 35 6 cm 6 1 m CPVC 25 4 cm 6 1 m STAINLESS 14 20 GABE on Ney 2 SEALED 35 6 cm 6 1 m CPVC 30 5 cm 6 1 m GAL STEEL STAINLESS 16 20 PVC ABS OR 12 20 SEALED 40 6 cm 6 1 m CPVC 30 5 cm 6 1 m WARNING No substitutions of flue pipe or vent cap material are allowed Such substitutions would jeopardize the safety and health of inhabitants A maximum of two elbows
88. tem it must be installed so that the chilled medium is piped in parallel with the boiler Appropriate valves manual or motorized must be provided to prevent the chilled medium from entering the boiler Water temperature in the heating system must be reduced to less than 100 F before cooling system is started or damage to the chiller unit may occur If the boiler is connected to chilled water piping or heating coils exposed to refrigerated air the boiler piping system must be equipped with flow control valves or other automatic means to prevent gravity circulation through the boiler during the cooling cycle Primary secondary pumping of both the chiller s and the boiler s is an excellent winter summer change over method because cooling flow rates are much more than heating flow rates In this way each system heating or cooling is circulated independently SPACE HEATING APPLICATIONS Controlling of these systems is decided mainly by the type of building system controlling that is desired A single boiler WATER PRESSURE REDUCING VALVE BYPASS FOR FAST FILL RESET CONTROL amp SEQUENCE PANEL OUTDOOR SENSOR SUPPLY TO BUILDING PROBE TYPE LOW WATER CUT OFF IF REQUIRED AIR SEPARATOR PRIMARY CIRCULATING PUMP Figure 10 Single or Multiple Boiler Installation Diagram 16 installation might be controlled directly from space temperature thermostat s Multiple boiler installations ar
89. ter Multiple boiler installations are especially adapted to the use of outdoor reset for main water temperatures This feature is not EXPANSION TANK CONNECTIONS AS CLOSE TOGETHER AS POSSIBLE THE DISCHARGE OF PRV NEEDS TO BE PROPERLY DRAINED ADDITIONAL BOILERS AS BUILDING LOAD MAY REQUIRE mandatory but offers smooth efficient operation of a modern system Normal use of flow control valves is required to prevent cross circulation of zones as with any multiple pump system Large systems with multiple boilers should include main water temperature controls with or without outdoor reset to sequence the boiler on and off in relation to the load on the system 24 VAC System Controller Optional GB models require a field supplied 24VAC operating control to be installed in the system such as loop thermostat indoor outdoor reset control sequencing panel or energy management system The connection for such devices is located in the 24 VAC junction box at the rear of the unit A 24 VAC thermostat aquastat can only be used as an On Off switch for the unit The actual controlling of the staging will be through either the inlet or tank probe To use a 24 VAC system controller dip switch E on the CCB must be switched to the position See figure 14 INTERNAL CONTAMINANTS The system must be internally cleaned and flushed after a new or replacement unit has been installed to remove contaminants that may have accumulat
90. tion on combustible flooring use the Combustible Floor Kit The combustible floor kit base adds 4 10 1 cm to the overall height of the boiler See figure 3 COMBUSTIBLE FLOOR KIT BASE MODEL GB GW 1000 GB GW 1300 GB GW 1500 COMBUSTIBLE FLOOR KIT NO 211093 211093 1 211093 2 GB GW 1850 211093 3 GB GW 2100 GB GW 2500 211093 4 211093 5 Figure 3 Boiler on Combustible Floor Base and Kit Numbers LEVELLING Each unit must be checked after installation to be certain that it is level AIR REQUIREMENTS A WARNING FOR SAFE OPERATION AN AMPLE SUPPLY OF AIR MUST BE PROVIDED FOR PROPER COMBUSTION AND VENTILATION IN ACCORDANCE WITH THE NATIONAL FUEL GAS CODE ANSI Z223 1 OR CAN CSA B149 1 AND 2 LATEST EDITIONS OR APPLICABLE PROVISIONS OF THE LOCAL BUILDING CODES AN INSUFFICIENT SUPPLY OF AIR MAY RESULT IN A YELLOW LUMINOUS BURNER FLAME CARBONING OR SOOTING OF THE FINNED HEAT EXCHANGER OR CREATE A RISK OF ASPHYXIATION DO NOT OBSTRUCT THE FLOW OF COMBUSTION AND VENTILATION AIR UNCONFINED SPACE In buildings of conventional frame brick or stone construction unconfined spaces may provide adequate air for combustion If the unconfined space is within a building of tight construction buildings using the following construction weather stripping heavy insulation caulking vapor barrier etc air for combustion ventilation must be obtained from outdoors or spaces freely communicating with the out
91. ystem will have one Central Control Board one Display Board and either three or four Ignition Control Boards depending on the model There will be one Ignition Control Board per stage The central control board contains a strip of dip switches which allow the user to control several system variables Table 5 shows a summary of these options Make sure the dip switches are the appropriate position for the unit s application Consult the Control System section of the manual for more information see page 26 DIP SWITCH CONFIGURATION TABLE OFF ON SELECTION 3 STAGE 4 STAGE EITHER 3 OR 4 STAGE SYSTEM 3 TRIALS 1 TRIAL EITHER3 OR 1 NOIRI IRI WHETHER SYSTEM IS IRIOR GAS VALVE GAS VALVE STANDARD INLET TANK INLET OR TANK AS CONTROLLING PROBE WHETHER EXTERNAL THERMOSTAT IS USED OUTLET MAXIMUM TEMPERATURE MAX SET POINT TEMPERATURE EITHER F OR FOR DISPLAYED TEMPERATURE NO EXTERNAL EXTERNAL THERMOSTAT THERMOSTAT OUTLET 210 F OUTLET 240 F 190 F 220 F DEGREES F DEGREES Figure 2 Summary of Dip Switch Options DIFFERENTIAL PRESSURE SWITCH The differential pressure switch ensures that a sufficient differential exists between the air pressure in the pre mix chamber and the inlet of the burner for safe low NOX combustion The switch has two pressure taps marked positive and negative Silicone tubing is run from the positive pressure tap of the switch to a tap on t

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