A.O. Smith 400 - 2100 Page 6 Installation & Operation Manual Download

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Installation & Operation Manual

The Genesis - How it works...

IMG00570

Models 400 - 750 Front View

Models 400 - 750 Left Side (inside unit)

Models 400 - 750 Right Side (inside unit)

Models 400 - 750 Rear View

IMG00571

IMG00572

IMG00573

Summary of Contents for 400 - 2100

Page 1: ...Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electr...

Page 2: ...ting 17 19 Vertical Vent Ducted Air 20 22 Sidewall Power Venting 23 25 Sidewall Power Venting Ducted Air 26 Direct Vent Sealed Combustion 27 30 Outdoor Installation 31 3 GAS CONNECTIONS Connecting to...

Page 3: ...rvice agency or the gas supplier Special instructions REMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS Avoid breathing dust and contact with skin and eyes Use NIOSH certified dust respirator N95 Th...

Page 4: ...See Section 7 Operating Information Freeze Protection for more information Safety information 1 This unit is only for use with the type of gas indicated on the rating plate 2 If you smell gas shut off...

Page 5: ...NPT Please reference the National Fuel Gas Code charts for connection details 14 Hot surface ignition module The hot surface ignition module controls the blower s hot surface igniter and gas valves A...

Page 6: ...How it works IMG00570 13 26 18 18 Models 400 750 Front View Models 400 750 Left Side inside unit Models 400 750 Right Side inside unit Models 400 750 Rear View IMG00571 15 IMG00572 14 8 17 9 21 24 19...

Page 7: ...rks continued Models 1000 2100 Left Side inside unit Models 1000 2100 Right Side inside unit Models 1000 2100 Rear View Models 1000 2100 Front View IMG00574 13 26 18 18 IMG00575 15 25 IMG00576 24 4 8...

Page 8: ...eet above sea level up to 4 500 feet Consult the factory for installations above 4 500 feet elevation Genesis AHRI Rating Model Number Note N Natural P Propane Input MBH Note 3 Min Max Gross Output MB...

Page 9: ...appliance directly on carpeting or other combustible material 9 Maintain required clearances from combustible surfaces reference the Indoor Clearances from Combustible Construction Section this page 1...

Page 10: ...be installed to prevent snow and ice ac cumulation around the unit or its venting system Outdoor installation Combustion air options CAUTION Under no circumstances should the equipment room ever be u...

Page 11: ...ee FIG 1 5 Each of the two openings must have a net free area of one square inch per 1000 Btu input 22cm2 per kW but not less than 100 square inches 645cm2 Figure 1 4_Outside Combustion Air Two Openin...

Page 12: ...OMBUSTION AIR SUPPLY TO EQUIPMENT ROOM Model Number Outside Air from 2 Openings Directly from Outdoors Outside Air from 1 Opening Directly from Outdoors in2 Inside Air from 2 Ducts Delivered from Outd...

Page 13: ...stion air inlet from either the back or right side of the unit To arrange the combustion air inlet for side entry follow the steps below 1 Remove the metal panel from the unit s side wall see FIG 1 7...

Page 14: ...oduction in the vent CAT IV Positive pressure condensing An appliance that operates with a positive vent static pressure with a vent gas temperature that may cause excessive condensate production in t...

Page 15: ...ination with air supplied from the equipment room see page 23 This option uses the installation of a special air inlet vent cap on top of the unit see page 31 IMG00580 IMG00583 NOTE CAT I B VENT MATER...

Page 16: ...system to prevent sagging Provide an upward slope of at least 1 4 inch per foot 21mm m on all horizontal runs from the unit to the vertical flue run or to the vent terminal on sidewall venting install...

Page 17: ...e venting tables for double wall vent to properly size all vent connectors and stacks Follow the vent manufacturer s instructions when installing Type B vents and accessories such as firestop spacers...

Page 18: ...ill result in condensing of flue products damage to the masonry flue tile insufficient draft and possible spillage of flue products into an occupied living space Carefully inspect all chimney systems...

Page 19: ...vents are installed with vent terminations recommended by the vent manufacturer Figure 2 2_Vent Termination from Peaked Roof 10 ft or More From Ridge Figure 2 4_Vent Termination from Flat Roof 10 ft...

Page 20: ...unit only See Table 2B page 22 for kit numbers Locate the unit as close as possible to the sidewall where you will install the combustion air supply system WARNING Locate and install the combustion ai...

Page 21: ...e air inlet termination elbow at least 12 30cm above the roof or above normal snow levels If the air inlet cap is within a 10 foot 3 05m radius of the flue outlet the point of termination for the comb...

Page 22: ...oducts can cause personal injury or death due to carbon monoxide poisoning For single unit installations with sidewall air inlet you must order the sidewall air inlet kit from the appliance manufactur...

Page 23: ...connectors thimbles caps etc When planning the venting system avoid possible contact with plumbing or electrical wiring inside walls The maximum installed length of sidewall vent pipe with an induced...

Page 24: ...or window or gravity air inlet into any building Locate vent termination at least 8 feet 2 4m horizontally from any combustion air intake located above the sidewall termination cap This vent system ha...

Page 25: ...le to chimney or gas vent When a vent system is disconnected for any reason the flue must be reassembled and resealed according to the vent manufacturer s instructions The installed length of flue fro...

Page 26: ...nt Kit for sidewall installation from the appliance manufacturer See Table 2D for kit numbers Each kit includes a sidewall powered vent cap fan proving switch controls combustion air inlet cap to supp...

Page 27: ...drain tubing Prime the trap loop by pouring a small quantity of water into the drain hose before assembly to the vent Secure the trap loop in position with nylon wire ties Use caution not to collapse...

Page 28: ...e an air space clearance of 2 inches 5 1cm around the flue pipe The diameter of the opening for installation of the sidewall cap will be 4 inches 10 2cm larger minimum than the nominal diameter of the...

Page 29: ...ter VERTICAL DV BOX ADAPTER HORIZONTAL DV BOX ADAPTER Air inlet piping materials The air inlet pipe s must be sealed Select air inlet pipe material from the following specified materials PVC CPVC or A...

Page 30: ...the first elbow The outlet of the second 90 elbow will be pointing down You may use a 90 elbow and a 90 straight elbow to make this assembly If you use a straight piece of pipe between the two 90 elbo...

Page 31: ...operational problems bad combustion or damage to controls Locate unit at least 3 feet 0 91m from any wall or vertical surface to prevent wind conditions from affecting performance Multiple unit outdo...

Page 32: ...u must adjust regulator pressure follow the instructions under Gas Manifold Pressure Adjustment in the Genesis Service Manual Do not increase regulator pressure beyond specified pressure setting Gas c...

Page 33: ...2 2 1 2 2 1 2 750 1 1 2 2 2 2 1 2 3 1000 2 2 2 1 2 2 1 2 3 1250 2 2 1 2 2 1 2 3 3 1450 2 1 2 2 1 2 3 3 3 1 2 1800 2 1 2 3 3 3 1 2 3 1 2 2100 2 1 2 3 3 3 1 2 4 For each elbow or tee add equivalent stra...

Page 34: ...supply pressures 9 If gas pressure is out of range contact gas utility gas supplier qualified installer or service agency to determine necessary steps to provide proper gas pressure to the control 10...

Page 35: ...code requirements for a low water cutoff device on water heaters requiring forced circulation for operation Low water cutoff if equipped If this unit is installed above radiation level a low water cu...

Page 36: ...quiet efficient operation Pump selection is critical to achieve proper operation A pump should be selected to achieve proper system design water temperature rise Two heat exchanger head loss charts FI...

Page 37: ...ure spikes and mechanical component failures To prevent short cycling of the water heater it is important to limit the cycles to six or fewer per hour TABLE 4B WATERHEATERTEMPERATURERISEATMAXIMUMFLOW...

Page 38: ...only Type T wire 63 F 35 C rise on all wiring between the unit and field installed devices 2 Encloselinevoltagewireexteriortotheunitinapproved conduit or approved metal clad cable 3 The pump must run...

Page 39: ...onic control should be set to Sequencer Mode 3 to act as an additional high limit control This will prevent problems between the setpoints of the EMS and the water heater s internal controller Termina...

Page 40: ...pump delay Remote mounting of a sensor To mount remote sensor follow the guidelines below Take care to correctly wire sensors to the unit Erratic temperature readings can be caused by poor wiring prac...

Page 41: ...odels 1000 2100 Verify by checking temperature rise while burner is firing at 100 of rated input 6 Installamanometeronthegassupplytothewaterheaterand verify minimum gas supply pressure as the burner f...

Page 42: ...eshooting Section of the Genesis Service Manual The venting system must be installed so that it will prevent flue gas spillage and carbon monoxide emissions which will result in severe personal injury...

Page 43: ...e safety information above on this label 2 Turn off all electric power to the appliance 3 Open control access panel 4 This appliance is equipped with an ignition device which automatically lights the...

Page 44: ...system needs by adjusting control parameters These parameters set operating temperatures and appliance operating modes Water heater operation can be based on a tank sensor or an external sequencer dev...

Page 45: ...Adjust Menu and the ADJUST segment is turned on in the display The display will automatically revert back to the View Menu after 20 seconds of keypad inactivity Once in a menu there will be a group of...

Page 46: ...of operation Mode 2 for standalone operation and Mode 3 for external sequenced operation The mode of operation is selected using the MODE item in the Adjust menu Mode 2 Standalone Operation This is t...

Page 47: ...ult is 2 F DIFF 2 Stage 2 differential Selection is from 2 to 42 F Factory default is 2 F STG DLY Advanced dipswitch position Delay between stages Selection is from 0 00 to 5 00 minutes in 10 second i...

Page 48: ...UST Dem 023 BOIL ADJUST Dem ON TANK T Mode 2 Boil Max Target 1 Setpoint Target 1 Diff Target 2 Setpoint Target 2 Diff Min DeltaT Pump Off 4 DIFF F 2 135 F TARGET 2 2 DIFF F I 135 F TARGET I 200 BOIL M...

Page 49: ...ISE SETTING EXCEEDED OPn BOIL OUT SHr BOIL OUT VIEW F I 2 Dem SHr VIEW F TANK I 2 Dem OPn TANK SHr BOIL IN VIEW F I 2 Dem OPn BOIL IN Err MAX T E01 EEPROM POSSIBLY CORRUPT E02 FREEZE PROTECTION Figure...

Page 50: ...panel after correcting ignition problem Initial heater start up without properly bleeding air from the gas line may require multiple reset functions to achieve proper ignition Four Flashes Igniter fai...

Page 51: ...he ignition module will go into a soft lockout if conditions of low air low voltage or low hot surface igniter current are present A soft lockout condition will operate the combustion air fans for the...

Page 52: ...heat exchanger must be manually set before normal operation begins If higher flow rates are required through the water heater an optional Cupro Nickel heat exchanger is available Consult the factory...

Page 53: ...ssolved solids water may require a larger circulating pump an optional Cupro Nickel heat exchanger and a revised temperature rise specification based on the water chemistry of the water to be heated W...

Page 54: ...PREFERRED PIPING LAYOUT 2 THE TEMPERATURE AND PRESSURE RELIEF VALVE SETTING SHALL NOT EXCEED PRESSURE RATING OF ANY COMPONENT IN THE SYSTEM 3 SERVICE VALVES ARE SHOWN FOR SERVICING WATER HEATER HOWEV...

Page 55: ...ED PIPING LAYOUT 2 THE TEMPERATURE AND PRESSURE RELIEF VALVE SETTING SHALL NOT EXCEED PRESSURE RATING OF ANY COMPONENT IN THE SYSTEM 3 SERVICE VALVES ARE SHOWN FOR SERVICING WATER HEATER HOWEVER LOCAL...

Page 56: ...PIPING LAYOUT 2 THE TEMPERATURE AND PRESSURE RELIEF VALVE SETTING SHALL NOT EXCEED PRESSURE RATING OF ANY COMPONENT IN THE SYSTEM 3 SERVICE VALVES ARE SHOWN FOR SERVICING WATER HEATER HOWEVER LOCAL CO...

Page 57: ...OUT 2 THE TEMPERATURE AND PRESSURE RELIEF VALVE SETTING SHALL NOT EXCEED PRESSURE RATING OF ANY COMPONENT IN THE SYSTEM 3 SERVICE VALVES ARE SHOWN FOR SERVICING WATER HEATER HOWEVER LOCAL CODES SHALL...

Page 58: ...er flow Proper pipe size between the heater and storage tank MUST be maintained to ensure that the standard pump supplied on the water heater will maintain desired flow TABLE 8C COMMON WATER MANIFOLD...

Page 59: ...e from the Operator Interface for water heater operation is 190 F 88 C The control is factory pre set at approximately 120 F 49 C Facilities with small children or invalids may require 120 F 49 C or a...

Page 60: ...panel as shown in FIG 8 6 The setting of this control knob limits maximum discharge water temperature The water heater temperature limit control is adjustable up to a maximum setting of 210 F 99 C Thi...

Page 61: ...and Operation Manual If combustion or performance indicate need Clean heat exchanger with a stiff bristle brush Remove and clean burners using water Dry before re assembling Clean the blower wheel wit...

Page 62: ...in sections reducing heat transfer overheating heat exchanger and causing heat exchanger failure Leaking water may also cause severe property damage 1 Inspect all water and gas piping and verify to b...

Page 63: ...operly replace the relief valve Ensure that the reason for relief valve weeping is the valve and not over pressurization of the system due to expansion tank waterlogging or undersizing WARNING WARNING...

Page 64: ...operly installed and adjusted units seldom need flue cleaning All gaskets sealants on disassembled componentsorjacketpanelsmustbereplaced with new gaskets sealants on reassembly Gasket and sealant kit...

Page 65: ...rs if removed from the unit Note Make sure frame runners seal securely where they contact the front and rear compartment refractory 10 Carefully reinstall inner jacket panels burners manifolds wires a...

Page 66: ...3 4 2 3 4 1 W BK W W Y C NO C NO NC BK R 9 8 7 6 4 3 2 1 10 5 O BK BR W BR W O BK 1 2 PR 2 1 O BK W R BK O PR GY GY BR BL Y 24VCOM 24VAC 120VAC 120VAC 2 12 24VCOM 24VAC BL 120VNEU 120VAC 24VAC 24VCOM...

Page 67: ...BK BL BL BK BL Y W 24V COMMON GROUND 120VAC 120VNEU 24VCOM 24VAC LWCO CONNECTOR LWCO CONNECTION T T SINGLE SPEED BLOWER BK W 0500 0750 2100 R BK Y R BL O O OPTIONAL R O G O BK O 4 3 2 1 BL Y 24VCOM 24...

Page 68: ...CAL SHOCK ENSURE ALL BRANCH CIRCUITS ARE DE ENERGIZED BEFORE ATTEMPTING TO SERVICE THIS EQUIPMENT WHERE POSSIBLE SW UTILITIES GAS W CONNECTED TO THE U MAY VARY FROM T DEPENDING UPON CONNECTED OR FAULT...

Page 69: ...M FOR ADDITIONAL NOTES W BL 1 4 3 2 R Y Y Y FACTORY FLOW SWITCH AUX HI LIMIT NO NC C O O BK O C NO O PR BK FF 1 T T W R BK 1 2 1 2 1 2 1 2 HIGH LOW FIRE RELAY W W LOUVER CONTACTS LOUVER PROVING LV LM...

Page 70: ...Installation Operation Manual 70 Notes...

Page 71: ...or and returning the claimed defective part to such distributor c All cost necessary or incidental for any material and or permits required for installation of the replacement 4 LIMITATIONS ON IMPLIED...

Page 72: ...Revision Notes Revision A ECO C1XXXX initial release GNS I S Rev A 03 13...

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A.O. Smith 400 - 2100, Installation & Operation Manual

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