background image

11

Figure 5. Vent Termination Installation Clearances

 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.

STANDARD VENTING

DIRECT VENT APPLICATIONS

Note:  Venting system of other than
direct-vent appliance shall terminate at
least 4 ft. (1.2 m) below, 4 ft. (1.2 m)
horizontally from, or 1 ft. (30.0 cm)
above any door window or gravity air
inlet.

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 Z223.1 or CAN/CSA-B149.1
(current edition), or applicable provisions of the local building
codes.

INTAKE /EXHAUST INSTALLATION REQUIREMENTS

1. The termination must be 12 inches (30.5 cm) above snow

or grade level whichever is higher.

2. Due to normal formation of water vapor in the combustion

process, horizontal terminations must not be located over
areas of pedestrian or vehicular traffic, i.e. public walkways
or over areas where condensate could create a nuisance
or hazard. This is especially true in colder climates where
ice buildup is likely to occur.  A.O. Smith Corporation will
not be held liable for any personal injury or property
damage due to any dislodging of ice.

3. The exhaust terminal of the venting system must maintain

a minimum clearance of 4 feet (1.22 m) horizontally from,
and in no case above or below, unless a 4-foot horizontal
distance is maintained, from electric meters, gas meters,
regulators and relief equipment.

4. The minimum distance from inside corner formed by two

exterior walls is 6 feet (1.8 m) but 10 feet (3.1 m) is
recommended where possible.

5. Maintain a minimum distance of 4 feet (1.2 m) from any

soffit or eve vent to the exhaust terminal.

6. Maintain a minimum distance of 10 feet (3.1 m) from

any forced air inlet.  Fresh air or make up air inlet such
as a dryer or furnace area is considered to be a forced
air inlet.

7. Avoid areas where condensate drainage may cause

problems such as above planters, patios, or adjacent to
windows where the steam from the flue gases may cause
fogging.

8. Select the point of wall penetration where the minimum

1/4" per foot (2 cm/m) of slope up can be maintained.

9. The through the wall termination kit is suitable for zero

clearance to combustible materials.

10. The mid point of the termination elbow must be a minimum

of 12 inches (30.5 cm) from the exterior wall.

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 16 -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 18-20; see Figures 11 and 13.
Installations must comply with all local codes.

INSTALLATION AS BOILER REPLACEMENT

Installation as boiler replacement on an old system with large water

Summary of Contents for 400 Series

Page 1: ...tion 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 PAGE DIMENSIONS CAPACITIESDATA 2 3...

Page 2: ...ater Conn Gas Inlet Model Natural Gas Natural Gas Propane Gas Propane Gas Inches cm Inches cm Size GW GB 1000 990 000 289 95 990 000 289 95 10 25 4 8 20 3 2 1 2 NPT 2NPT GW GB 1300 1 300 000 380 74 1...

Page 3: ...62 9 31 6 80 3 82 208 3 15 5 39 4 39 75 101 58 25 148 15 9 40 83 16 40 64 57 3 145 5 GBO GWO 1500 30 76 2 31 6 80 3 89 226 15 5 39 4 39 75 101 58 25 148 15 9 40 83 16 40 64 64 3 163 3 GBO GWO 1850 27...

Page 4: ...TALLATION TO AVOID POSSIBLE ERRORS AND MINIMIZE TIME AND MATERIALS COST SEE FIGURES 1 THROUGH 5 AND TABLES 1 2 AND 3 This design complies with the current edition of ANSI Z21 13 CSA 4 9 for Gas Fired...

Page 5: ...ery system will have one Central Control Board CCB one Power Distribution Board PDB one User Interface Module UIM and either two or three Flame Control Boards FCB depending on the model The Control Bo...

Page 6: ...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 blower...

Page 7: ...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 P relief valve a in t...

Page 8: ...Control Board Flame Control Boards Power Distribution Board and wiring harnesses is provided through a panel on the left side of the unit A minimum service clearance of 18 46 0 cm is required These b...

Page 9: ...unicating 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 Bt...

Page 10: ...ve 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...

Page 11: ...gas meters regulators and relief equipment 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...

Page 12: ...of the vent shall be supported to maintain clearances and to prevent physical damage or separation of joints TABLE 10 STANDARD VERTICAL VENTING CATEGORY I Extending venting over 70 feet 21 3 m may re...

Page 13: ...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 500 Tennessee Waltz Parkway Ashland City TN 37015 Phone...

Page 14: ...vent terminal The horizontal portion of the vent shall be supported to maintain clearances and to prevent physical damage or separation of joints Figure 8 APPLIANCE CERTIFIED EXHAUST VENT MAXIMUM AIR...

Page 15: ...2515 Pipe joints must be positively sealed TABLE 13 DIRECT VENT HORIZONTAL EXHAUST CONFIGURATIONS Figure 9 APPLIANCE CERTIFIED EXHAUST MAXIMUM AIR INTAKE AIR INTAKE MAXIMUM MODEL CATEGORY EXHAUST VENT...

Page 16: ...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 incre...

Page 17: ...le 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 heatin...

Page 18: ...he tank probe as the controlling probe Second Dip Switch SW1 1 must be set to the OFF position to limit the maximum tank probe temperature for GW applications Failure to do this will void the warranty...

Page 19: ...WATER FLOW SWITCH PROTECTS THE BOILER IN CASE OF WATER SERVICE INTERRUPTION OR CIRCULATOR FAILURE PIPE TO OPEN DRAIN X FACTORY INSTALLED ON UNIT SUPPLIED WITH UNIT FIELD INSTALLED INSTALL THERMAL EXP...

Page 20: ...ED DANGER TEMPERATURE SETTING SHOULD NOT EXCEED SAFE USE TEMPERATUREAT FIXTURES SEE WATER TEMPERATURE CONTROL WARNING ON PAGE 26 IF HIGHER PREHEAT TEM PERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTE...

Page 21: ...92 2 841 2 577 2 372 2 197 2 109 1 962 1 757 1 611 1 464 1 347 Length of Pipe in Feet Metres Nominal Iron Pipe Size Cap 10 Ft 20 Ft 30 Ft 40 Ft 50 Ft 60 Ft 70 Ft 80 Ft 90 Ft 100 Ft 125 Ft 150 Ft 175 F...

Page 22: ...and30Amps TABLE 18 Orifice Size for Natural and Propane LP Gases U S and Canada Installations for high altitude up to 4 500 ft 1 372 m Drill Size Input Rating Number of Model BTU HR Burners Natural 4...

Page 23: ...23 GB GW 2100 GB GW 2500 GB GW 1000 1500 GAS MANIFOLD ASSEMBLY GB GW 1850 Figure 14 GB GW 1000 2500 Gas Manifold Assembly Diagrams...

Page 24: ...24 GENESIS GB GW 1000 2500 SERIES 400 WIRING DIAGRAM FIGURE 15...

Page 25: ...25...

Page 26: ...26 GENESIS GB GW 1000 2500 SERIES 400 SCHEMATIC DIAGRAM FIGURE 16...

Page 27: ...27...

Page 28: ...28 Figure 17 CCB CENTRAL CONTROL BOARD...

Page 29: ...29 Figure 18 FCB FLAME CONTROL BOARD Diagram...

Page 30: ...30 Figure 19 PDB POWER DISTRIBUTION BOARD Diagram...

Page 31: ...Installation 1 Close the systems drain valve 2 Open a nearby hot water faucet to permit the air in the system to escape 3 Fully open the cold water inlet pipe valve allowing the heater and piping to...

Page 32: ...OLLER TO THE LOWEST SETTING 2 TURN POWER SWITCH ON APPLIANCE TO OFF POSITION 3 REMOVEACCESSPANELTOEXPOSEGASCONTROL IF YOU CANNOT REACH YOUR GAS SUPPLIER CALL THEFIREDEPARTMENT C USE ONLYYOUR HAND TO P...

Page 33: ...A QUALIFIED SERVICETECHNICIANTOINSPECTTHEAPPLIANCEAND TOREPLACEANYPARTOFTHECONTROLSYSTEMAND ANYGASCONTROLWHICHHASBEENUNDERWATER E DO NOT OPERATEAPPLIANCE UNLESS UNIT IS FILLED WITH WATERAND WATER LINE...

Page 34: ...dition occur the control will shut down the burner and display a red fault light as well as indicate the cause of the fault on the display The operating programs for the system are stored in permanent...

Page 35: ...l Normally open switch that closes when the IRI Gas Valve is operating correctly This input is enabled disabled by a dipswitch on the CCB Flame Sensor Flame CCB required Returns a signal to the microp...

Page 36: ...ns If a switch is changed power must be cycled before the change will take effect The status of all dipswitches can be observed on the system status screen on the UIM CCB FCB Dipswitches Dipswitches F...

Page 37: ...om the controlling probe inlet or tank to the setpoint temperature If the temperature is less than the operating setpoint minus the differential temperature and the thermostat input is closed then a c...

Page 38: ...l which means that it will begin heating the water when the temperature sensed by the control probe inlet or tank falls below the operating setpoint minus the differential setpoint for stage 1 It will...

Page 39: ...been satisfied or the Thermostat is opened the sequence moves to Post Circulate and then back to Idle If a fault occurs at any time the process jumps out of sequence and goes directly to the appropri...

Page 40: ...iter hardware failure If the igniter does reach the minimum required amp draw of 2 8 amps the gas valve circuit is energized and the system advances to Flame Check status Check for Flame State The gas...

Page 41: ...and minutes This error remain displayed as long as it is still valid When cleared it is moved to the Error History Screen The system will automatically jump to this screen OPERATING SETPOINT ADJUSTME...

Page 42: ...keys or press Menu key to go to the menu screen If a small down arrow appears in the lower right hand corner then there is off screen content below what is displayed Press the down arrow to scroll do...

Page 43: ...checked by disconnecting the outlet probe from the CCB and reading the resistance across the two active pins on the connector at the end of the probe cable The value should be approximately 0 ohms whe...

Page 44: ...rner venturi and ports are free of foreign matter 4 Clean burners with bristle brush and or vacuum cleaner DO NOT distort burner ports 5 Reinstall burners in unit Ensure that all the screws on the bur...

Page 45: ...y 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 Periodically clean air filte...

Page 46: ...einstall return header casting Flush system Note Removal of the heat exchanger is not required CAUTION IF HEAT EXCHANGER MAINTENANCE REQUIRES TUBING REPLACEMENT SPECIAL PROVISIONS SHALL BE TAKEN TO EN...

Page 47: ...WARRANTIES Implied warranties including any warranty of merchantability imposed on the sale of this boiler under state law are limited to one 1 year duration for the boiler or any of its parts Some st...

Page 48: ...48 500 Tennessee Waltz Parkway Ashland City TN 37015 Phone 800 433 2545 www hotwater com E Mail parts hotwater com...

Reviews: