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PRINTED IN U.S.A. 0906

COPPER BOILERS FOR

HYDRONIC HEATING AND

HOT WATER SUPPLY

     

CAUTION

TEXT PRINTED OR OUTLINED IN RED CONTAINS
INFORMATION RELATIVE TO YOUR SAFETY.
PLEASE READ THOROUGHLY BEFORE INSTALLING
AND USING THIS APPLIANCE.

212511-000

MC BEE, SC., RENTON, WA.,

STRATFORD-ONTARIO,  VELDHOVEN-THE NETHERLANDS,

NANJING, CHINA

www.hotwater.com / email:[email protected]

PLACE THESE INSTRUCTIONS ADJACENT TO BOILER AND

NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.

Installation

Operation

Maintenance

Limited Warranty

Instruction Manual

GB/GW 

MODELS

:

1000, 1300, 1500, 1850, 2100, 2500

SERIES: 400, 401, 402, 403, 404, 405

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.

Thank Y

ou

 for buying this cost

efficient, high recovery unit from

A. O. Smith Water Products Co.

You should thoroughly read and understand 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

PAGE

DIMENSIONS/CAPACITIES DATA .......................... 2 - 3
FOREWORD ......................................................... 4 - 5
FEATURES/CONTROLS .....................................  5 - 7
INSTALLATION INSTRUCTIONS .......................  7 - 9
VENTING ...........................................................  9 - 11
SYSTEM INSTALLATION ................................ 11 - 16
HYDRONIC INSTALLATION ............................ 16 - 18
HOT WATER SUPPLY INSTALLATION ........... 18 - 31
GAS CONNECTIONS ......................................  18 - 23
OPERATION ....................................................  31 - 34
LIGHTING AND OPERATING .......................... 32 - 33
CONTROL SYSTEM .......................................  34 - 44
PREVENTATIVE  MAINTENANCE ..................  44 - 46
TROUBLE SHOOTING .................................... 42 - 44
WIRING DIAGRAM/SCHEMATIC ...................  24 - 27
LIMITED WARRANTY ............................................. 47

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.

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...

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