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34

TABLE 20.  RISK OF SCALDS.

TEMPERATURE

TIME TO PRODUCE 2nd & 3rd

   SETTING

DEGREE BURNS ON ADULT SKIN

OVER 170°F (77°C)

NEARLY INSTANTANEOUS

160°F (71°C)

ABOUT 1/2 SECOND

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

MORE THAN 5 MINUTES

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.

CONTROL SYSTEM

The EMC 5000 control system is a fully integrated, state of the art
electronic control system. It consists of sensors, output devices, a
power switch, a 24vac transformer, wiring and the following printed
circuit boards:

• Central Control Board (CCB), see Figure 17.
• Flame Control Board (FCB), see Figure 18.
• Power Distribution Board (PDB), see Figure19.
• User Interface Module (UIM), see Figure 21.

The CCB contains circuitry for both master control and flame control
for the first stage. The FCB's contains circuitry for control on up to
three additional stages. Dipswitches on the CCB and FCB are used
to configure the system. The User Interface Module (UIM)
communicates with the user through a set of touch pads and a 4-
line, 20-character LCD display. The PDB provides connection points
for input power, the water pump, and the transformer. It also
distributes power to the system and contains the system fuses.

Multiple-stage control is accomplished by means of an internal
communications network between the CCB and the FCB's. One
FCB is required for each stage beyond the initial first stage. The
CCB also contains an external communications system to allow
for connection to a PC, a modem, an EMS system, or something
similar. Through this connection multiple boilers can also be linked
together. 

CAUTION: The internal communications cables should

never be connected to the external communications connectors
and vice-versa.

There are several microcontrollers used on the boards. These
micros control the temperature and ignition control functions for
the boiler. Inherent in the design are the normal operating
sequences and safety features associated with a gas ignition
control system. The system continuously performs various
diagnostic tests to verify proper appliance and control operation.
Should an unsafe condition occur, the control will shut down the
burner and 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 memory inside the micros. User-selectable
operating parameters and a history of detected faults are stored in
re-writable memory in the micros. A loss of power does not affect
either of the memories.

Inputs to CCB and FCB
Temperature Sensors:

• Temperature probes (CCB - outlet and either inlet or tank are

MANIFOLD PRESSURE

The manifold gas pressure is measured at the pressure tap on the
downstream side of the combination 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.

2. CHECK THE INPUT.  SEE NATIONAL FUEL GAS CODE, ANSI

Z223.1 OR CAN/CSA - B149.1 (CURRENT EDITION) 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 A CHILD OR DISABLED
PERSON UNATTENDED IN A BATHTUB OR SHOWER.

THE WATER HEATER SHOULD BE LOCATED IN AN AREA WHERE
THE GENERAL PUBLIC DOES NOT HAVE ACCESS TO SET
TEMPERATURES.

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 THE WATER TEMPERATURE BE SET FOR THE
LOWEST TEMPERATURE WHICH SATISFIES THE USER'S HOT
WATER NEEDS.  THIS WILL ALSO PROVIDE THE MOST ENERGY
EFFICIENT OPERATION OF THE 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 20
ABOVE SHOWS THE APPROXIMATE TIME-TO-BURN
RELATIONSHIP FOR NORMAL ADULT SKIN.

Содержание 400 Series

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 25: ...25...

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

Страница 27: ...27...

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

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

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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