A.O. Smith 1850 User Manual

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COPPER BOILERS FOR

HYDRONIC HEATING AND

HOT WATER SUPPLY

Installation

Operation

Maintenance

Limited Warranty

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 NOTIFYOWNERTOKEEPFORFUTUREREFERENCE.

Instruction Manual

GB/GW MODELS:

1000, 1300, 1500, 1850, 2100, 2500

SERIES 200, 201

CAUTION

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

You Thankfor 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

ROUGH-INDIMENSIONS/CAPACITIES

.............

2

- 3

FOREWORD .....................................................

 

4

- 5

FEATURES/CONTROLS ...................................

 

5

- 6

INSTALLATION INSTRUCTIONS ...................

6

- 22

VENTING .......................................................

8

- 14

SYSTEM INSTALLATION ..............................

15 - 19

HYDRONIC INSTALLATION ..........................

15 - 17

HOT WATER SUPPLY INSTALLATION .........

17 - 19

GAS CONNECTIONS ....................................

20 - 21

OPERATION ................................................

22

- 23

LIGHTINGANDOPERATING .........................

24 - 25

CONTROL SYSTEM ....................................

26

- 31

PREVENTATIVE MAINTENANCE ................

31

- 33

TROUBLE SHOOTING ..................................

33 - 34

LIMITED WARRANTY ..........................................

 

 

35

WIRING DIAGRAM/SCHEMATIC ..................

36

- 37

A DIVISION OF A. O. SMITH CORPORATION

EL PASO, TX., MC BEE, SC., RENTON, WA.,

STRATFORD-ONTARIO,VELDHOVEN-THENETHERLANDSwww.hotwater.com

PRINTED IN U.S.A. 2526 0501

1

PART NO. 211257-000REV. 0

 

 

 

ROUGH-INDIMENSIONS

TOP VIEW

FRONT VIEW

IMPORTANT!

Refer to "Installation Clearances" section of manual (page 7) for recommended service clearances prior to boiler placement.

LEFT SIDE

REAR VIEW

TABLE 1: GAS AND ELECTRICAL CHARACTERISTICS

Model

 

Manifold Pressure

 

Electrical Characteristics

 

 

 

 

 

 

 

 

Type of Gas

Inches W.C.

kPa

 

Volts/Hz

 

Amperes

 

 

 

 

 

 

 

 

GW/GB-1000

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

thru 2500

 

NATURAL

 

3.5

 

0.87

 

120/60

 

30

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

GW/GB-1000

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

thru 2500

 

PROPANE

 

 

10

 

2.49

 

120/60

 

30

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Figure 1.

 

 

 

 

 

 

TABLE 2. ROUGH - IN DIMENSIONS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

A

 

 

B

 

 

C

 

 

 

 

D

 

E

 

F

 

 

Model

 

Inches

c m

Inches

c m

Inches

 

c m

 

Inches

c m

Inches

c m

Inches

c m

 

 

GW/GB-1000

 

14.1

35.8

 

12.2

31.0

40.3

 

102.4

 

31.6

80.3

26.0

66.0

46.8

118.9

 

 

GW/GB-1300

 

24.8

63.0

 

12.2

31.0

40.3

 

102.4

 

31.6

80.3

39.3

99.8

57.3

145.5

 

 

GW/GB-1500

 

30.2

76.7

 

12.2

31.0

40.3

 

102.4

 

31.6

80.3

44.6

113.3

64.3

163.3

 

 

GW/GB-1850

 

27.7

70.4

 

11.2

28.4

43.0

 

109.2

 

32.3

82.0

44.0

111.8

78.3

198.9

 

 

GW/GB-2100

 

31.0

78.7

 

11.2

28.4

43.0

 

109.2

 

32.3

82.0

49.5

125.7

85.3

216.7

 

 

GW/GB-2500

 

38.1

96.8

 

10.5

26.7

43.0

 

109.2

 

32.3

82.0

56.5

143.5

99.3

252.2

 

 

Input

 

Exhaust

 

Inlet

 

 

 

BTU/Hr.

KW

BTU/Hr.

KW

Vent Diameter

Vent Diameter

Water Conn.

Gas Inlet

Model

Natural Gas

Natural Gas

Propane Gas

Propane Gas

Inches

c m

Inches

 

c m

Size

 

GW/GB-1000

990,000

289.95

990,000

289.95

10

25.4

8

 

20.3

2 1/2 NPT

2 NPT

GW/GB-1300

1,300,000

380.74

1,300,000

380.74

12

30.5

10

 

25.4

2 1/2 NPT

2 NPT

GW/GB-1500

1,500,000

439.31

1,500,000

439.31

12

30.5

10

 

25.4

2 1/2 NPT

2 NPT

GW/GB-1850

1,850,000

541.82

1,850,000

541.82

14

35.6

10

 

25.4

2 1/2 NPT

2 1/2 NPT

GW/GB-2100

2,100,000

615.04

2,100,000

615.04

14

35.6

12

 

30.5

2 1/2 NPT

2 1/2 NPT

GW/GB-2500

2,490,000

729.26

2,490,000

729.26

16

40.7

12

 

30.5

2 1/2 NPT

2 1/2 NPT

2

TABLE 3: RECOVERY CAPACITIES

 

 

 

 

Temperature Rise - Degrees °F (°C)

 

 

 

 

 

Input Rating

Gal/Liter

40°F

50°F

60°F

70°F

80°F

90°F

100°F

110°F

120°F

130°F

MODEL

BTU/Hr. (kW)

per Hr.

(22.2°)

(27.7°)

(33.3°)

(38.8°)

(44.4°)

(50°)

(55.5°)

(61.1°)

(66.7°)

(72.2°)

GW - 1000

990,000 (290.1)

LPH

9526

7620

6350

5443

4763

4234

3810

3462

3175

2930

 

 

GPH

2520

2016

1680

1440

1260

1120

1008

916

840

775

GW - 1300

1,300,000 (380.9)

LPH

12508

10006

8339

7148

6256

5560

5005

4547

4169

3848

 

 

GPH

3309

2647

2206

1891

1655

1471

1324

1203

1103

1018

GW - 1500

1,500,000 (439.5)

LPH

14432

11548

9620

8248

7216

6415

5772

5247

4812

4442

 

 

GPH

3818

3055

2545

2182

1909

1697

1527

1388

1273

1175

GW - 1850

1,850,000 (542.0)

LPH

17800

14239

11865

10172

8902

7912

7122

6471

5935

5477

 

 

GPH

4709

3767

3139

2691

2355

2093

1884

1712

1570

1449

GW - 2100

2,100,000 (615.3)

LPH

20204

16163

13472

11548

10104

8981

8082

7348

6736

6218

 

 

GPH

5345

4276

3564

3055

2673

2376

2138

1944

1782

1645

GW - 2500

2,490,000 (729.6)

LPH

23958

19168

15971

13691

11979

10648

9582

8713

7987

7371

 

 

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

 

 

GPM

PD-FT

GPM

PD-FT

GPM

PD-FT

GPM

PD-FT

Deg. F

GPM

PD-FT

Deg. F

MODEL

 

 

Head

 

Head

 

Head

 

Head

Rise

 

Head

 

Rise

GB - 1000

83.16

5.1

55.4

2.7

41.6

1.5

154

12.2

11

42

1.5

 

40

 

GB - 1300

109.2

7.2

72.8

4.2

54.6

3.2

154

14.5

14

55

3.2

 

40

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

GB - 1500

126

10.1

84

6.3

63

4.3

154

16.3

17

64

4.3

 

40

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

GB - 1850

154

18.5

103.6

10.1

77.7

6.4

154

18.5

20

78

6.4

 

40

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

GB - 2100

 

n/a

n/a

117.6

14.5

88.2

8.3

154

21.3

23

89

8.3

 

40

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

GB - 2500

 

n/a

n/a

139.4

18.5

104.6

11.6

154

23.2

28

105

11.6

 

40

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Note: GW models (GB optional) are equipped with pumps capable of handling 50 equivalent feet

 

 

 

 

 

(15.2 m) of normal pipe fittings.

 

 

 

 

 

 

 

 

 

3

FOREWORD

These designs comply with the latest edition of the American National Standards for Gas-Fired,Low-PressureSteam 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 installed 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 equipment grounding terminal or lead on the boiler.

WARNING

YOUR BOILER IS NOT DESIGNED TO OPERATE WITH A 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 A BYPASS 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:

1.EXPOSURE TO FIRE.

2.IF DAMAGED.

3.FIRING WITHOUT WATER.

4.SOOTING.

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 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

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-REGULATINGPREJET ORIFICES WHICH AUTOMATICALLY COMPENSATE FOR HIGHER ELEVATIONS AND ADJUST THE APPLIANCE'S INPUT RATE ACCORDINGLY, MAKING IT UNNECESSARY TO REPLACE ORIFICES FOR HIGH 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 m) ratings must be reduced by a rate of 4% for each 1,000 feet (300 m) above sea level.

4

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-STAGEFIRING 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 amulti-stagecontrol 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 system 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 in 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

SW1

OFF

ON

SELECTION:

 

A

3 STAGE

4 STAGE

EITHER 3 OR 4 STAGE SYSTEM

B

3 TRIALS

1 TRIAL

EITHER 3 OR 1

C

NOIRI

IRI

WHETHER SYSTEM IS IRI OR

 

GAS VALVE

GAS VALVE

STANDARD

D

INLET

TANK

INLET OR TANK AS

 

 

 

CONTROLLING PROBE

E

NO EXTERNAL

EXTERNAL

WHETHEREXTERNAL

 

THERMOSTAT

THERMOSTAT

THERMOSTATIS USED

F

OUTLET 210°F

OUTLET 240°F

OUTLETMAXIMUMTEMPERATURE

G

190°F

220°F

MAX. SET-POINTTEMPERATURE

H

DEGREES°F

DEGREES°C

EITHER °F OR °C FOR DISPLAYED

 

 

 

TEMPERATURE

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-mixchamber 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 the control panel to measure the air pressure in thepre-mixchamber. 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-mostburner. 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 CONTROLS

CAUTION

LIMIT CONTROLS ARE SAFETY DEVICES AND ARE NOT TO BE USED AS A THERMOSTAT.

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-buttonon the display panel to restart the boiler.

ON/OFF SWITCH

The ON/OFF switch is a single-pole,single-throwrocker 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-suppliedwires should be spliced to "pigtails" of tank probe and connected to terminal block in the 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

5

probe is not supplied with the GB models. A tank probe can 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-StageFiring 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 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.

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 DAMAGEA DRAIN LINE MUST BE CONNECTED TO A SAFETY RELIEF VALVE TO DIRECT DISCHARGE TO A SAFE LOCATION. A DRAIN 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 PURPOSE OF THE RELIEF VALVE AND MAY CREATE AN UNSAFE CONDITION. INSTALL A 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-offDevices for Hot Water Supply Systems, ANSI Z21.22 orCSA-4.4(and latest addendums). The valve must be of the automatic reset type and not embody asingle-usetype 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-ratedvalve 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-certifiedandASME-ratedtemperature and pressure (T & 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 T & P 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 & 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 & 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 protected from water (dripping, spraying, etc.) during appliance operation and service (circulator replacement, control replacement, etc.)

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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 NEAR A 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.

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 TRAVEL ALONG 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 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.

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.

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 installation 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.

 

 

MODEL

COMBUSTIBLE FLOOR KIT NO.

(GB/GW)-1000

211093

(GB/GW)-1300

211093-1

(GB/GW)-1500

211093-2

(GB/GW)-1850

211093-3

(GB/GW)-2100

211093-4

(GB/GW)-2500

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

WARNING

FOR SAFE OPERATION, AN AMPLE SUPPLY OF AIR MUST BE

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PROVIDED FOR PROPER COMBUSTION AND VENTILATION IN ACCORDANCE WITH THE NATIONAL FUEL GAS CODE, ANSI Z223.1 ORCAN/CSA-B149.1AND .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 outdoors. 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 crosssectional area shall be at least 10% of the area of the combustion air opening but in no case shall the cross-sectionalarea be less than 10 square inches (6500 mm2).

In addition to the above, there shall be permanent air supply opening(s) having a cross-sectionalarea of not less than 1 square inch per 7,000 BTUH (310 mm2/KW) up to and including 1,000,000 BTUHplus 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 OFASPHYXIATION.

VENTING

This boiler is approved to be vented as a Category I, 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

Horiz. or Horiz. Direct Vent Kit No.

Model Number

211090

G(W,B) 1000

211090-1

G(W,B) 1300

211090-1

G(W,B) 1500

211090-4

G(W,B) 1850

211090-2

G(W,B) 2100

211090-3

G(W,B) 2500

Vertical Direct Vent Kit No.

Model Number

211089

G(W,B) 1000

211089-1

G(W,B) 1300

211089-1

G(W,B) 1500

211089-4

G(W,B) 1850

211089-2

G(W,B) 2100

211089-3

G(W,B) 2500

CAUTION

WHEN 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 OF -0.02"W.C.ANDAMAXIMUM DRAFT OF-0.04"W.C. MUSTBE 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-1gas 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 steps 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.

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1.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, windows, 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 Z223.1 orCAN/CSA-B149.1and .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.

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 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 m) 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 elbow must be a minimum of 12 inches (30.5 cm) from the exterior wall.

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STANDARD VENT - VERTICAL (CATEGORY I)

IMPORTANT!

VENT PRESSURE MUST BE MAINTAINED BETWEEN -0.02"W.C. AND-0.04"W.C. AT 24" (61.0 cm) ABOVE BOILER COLLAR.

Figure 5.

TABLE 7. STANDARD VERTICAL VENTING (CATEGORY I)

 

APPLIANCE

CERTIFIED

EXHAUST

MAXIMUM LENGTH WITHOUT

MODEL

CATEGORY

VENTING

VENT SIZE

BAROMETRIC DAMPER (FEET)

 

 

MATERIAL

(INCHES)

 

I000

I

TYPE B OR

10”(25.4 cm)

35 Feet (10.7 m) without damper

EQUIVALENT

 

*70 Feet (21.3 m) max. with damper

 

 

 

1300

I

TYPE B OR

 

35 Feet (10.7 m) without damper

1500

EQUIVALENT

12" (30.5 cm)

*70 Feet (21.3 m) max. with damper

 

1850

I

TYPE B OR

14"(35.6 cm)

35 Feet (10.7 m) without damper

2100

EQUIVALENT

 

*70 Feet (21.3 m) max. with damper

 

 

2500

I

TYPE B OR

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 I appliances shall be determined per the latest edition of the National Fuel Code (U.S.) and CAN/CSA-B149.1and .2 Installation Code (Canada).

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 vent shall be supported to maintain clearances and to prevent physical damage or separation of joints.

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