A.O. Smith 400 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: 400, 401, 402, 403, 404, 405

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

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

MC BEE, SC., RENTON, WA.,

STRATFORD-ONTARIO,VELDHOVEN-THENETHERLANDS,

NANJING, CHINA www.hotwater.com / email:parts@hotwater.com

PRINTED IN U.S.A. 0906

1

212511-000

 

 

 

DIMENSIONS/CAPACITIES DATA

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 REQUIREMENT

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 during operating conditions.

Figure 1.

TABLE 2. DIMENSIONAL DATA

 

 

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 Rating

 

Exhaust

Air Intake

 

 

 

BTU/Hr.

KW

BTU/Hr.

KW

Vent Diameter

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

DIMENSIONS DATA FOR OUTDOOR CONFIGURATION

REAR VIEW

LEFT SIDE

FRONT VIEW

TOP VIEW

Figure 2.

TABLE 3. DIMENSIONAL DATA

 

A

 

B

 

C

 

D

 

E

 

F

 

G

 

H

 

J

Model

Inches

 

cm

Inches

 

cm

Inches

 

cm

Inches

 

cm

Inches

 

cm

Inches

 

cm

Inches

 

cm

Inches

 

cm

Inches

cm

GBO/GWO-1000

14

 

35.5

31.6

 

80.3

71.8

 

182.4

15.5

 

39.4

39.75

 

101

58.25

 

148

15.9

 

40.83

16

 

40.64

46.8

118.9

GBO/GWO-1300

24.75

 

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

27.5

 

69.9

32.3

 

82

103

 

261.6

18.9

 

48

43

 

109.2

61.5

 

156.2

23.9

 

60.7

20

 

50.8

78.3

198.9

GBO/GWO-2100

31

 

78.7

32.3

 

82

110

 

279.4

18.9

 

48

43

 

109.2

61.5

 

156.2

23.9

 

60.7

20

 

50.8

85.3

216.7

GBO/GWO-2500

38

 

96.5

32.3

 

82

124

 

315

18.9

 

48

43

 

109.2

61.5

 

156.2

23.9

 

60.7

20

 

50.8

99.3

252.2

3

TABLE 4: RECOVERY CAPACITIES

 

 

 

 

TEMPERATURE RISE - DEGREES °F (°C)

 

 

 

 

Input Rating

Water

40°F

50°F

60°F

70°F

80°F

90°F

100°F

110°F

120°F

130°F

MODEL

BTU/Hr. (kW)

Flow

(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)

GPH

2520

2016

1680

1440

1260

1120

1008

916

840

775

 

 

LPH

9526

7620

6350

5443

4763

4234

3810

3462

3175

2930

GW - 1300

1,300,000 (380.9)

GPH

3309

2647

2206

1891

1655

1471

1324

1203

1103

1018

 

 

LPH

12508

10006

8339

7148

6256

5560

5005

4547

4169

3848

GW - 1500

1,500,000 (439.5)

GPH

3818

3055

2545

2182

1909

1697

1527

1388

1273

1175

 

 

LPH

14432

11548

9620

8248

7216

6415

5772

5247

4812

4442

GW - 1850

1,850,000 (542.0)

GPH

4709

3767

3139

2691

2355

2093

1884

1712

1570

1449

 

 

LPH

17800

14239

11865

10172

8902

7912

7122

6471

5935

5477

GW - 2100

2,100,000 (615.3)

GPH

5345

4276

3564

3055

2673

2376

2138

1944

1782

1645

 

 

LPH

20204

16163

13472

11548

10104

8981

8082

7348

6736

6218

GW - 2500

2,490,000 (729.6)

GPH

6338

5071

4225

3622

3169

2817

2535

2305

2113

1950

 

 

LPH

23958

19168

15971

13691

11979

10648

9582

8713

7987

7371

TABLE 5: PUMPING PERFORMANCE GUIDE

 

 

 

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

5.1

55

2.7

41.6

1.5

154

12.2

11

42

1.5

40

GB - 1300

109

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

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.

FOREWORD

Detailed installation diagrams are in this manual. These diagrams will provide the installer with a reference of materials needed and a suggested method of piping. IT IS NECESSARY THAT ALL WATER AND GAS PIPING, AND THE ELECTRICAL WIRING BE INSTALLED AND CONNECTED AS SHOWN IN THE DIAGRAMS.

CHECK DIAGRAMS THOROUGHLY BEFORE STARTING INSTALLATION 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-CSA4.9 forGas-FiredLow-PressureSteam and Hot Water Boilers.

MAKE SURE THE GAS ON WHICH THE BOILER WILL OPERATE IS THE SAME AS THAT SPECIFIED ON THE BOILER RATING PLATE.

The boiler installation must conform to these instructions and the local code authority having jurisdiction. In the absence of local codes, the installation must comply with the latest editions of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and the National Electrical Code, NFPA 70 or CAN/CSA B149.1, and CSA 2 C22.1. The former is available from the Canadian Standards Association, 8501 East Pleasant Valley Road, Cleveland, OH 44131, and both documents are available from the National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02269.

4

GROUNDING INSTRUCTIONS

This boiler must be grounded in accordance with the National Electrical Code, NFPA 70 or the Canadian Electrical Code CSA 2 C22.1 and/or local codes. The 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 (49°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 UNTILALL 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. 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). 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.

Input rating specified on the rating plate applies to elevations up to 4,500 feet (1350 m). For elevations above 4,500 feet (1350 m), ratings must be reduced, consult the factory.

FEATURES/CONTROLS

MULTI-STAGEFIRING AND CONTROL SYSTEM

ALL MODELS - The control system consists of four basic components: 1) Central Control Board 2) Flame Control Board 3) User Interface Module 4) Power Distribution Board; see Figures 17, 18, 19 and 21. The Central Control Board, Flame Control Boards and the Power Distribution Board are located in the control box and can be accessed through panels on the left side and top of the unit. The User Interface Module is attached to the front jacket panel. The control system is amulti-stagecontrol capable of managing three or four firing stages. Models 1000, 1300, and 1500 operates with3-stagefire. Models 1850, 2100 and 2500 operates with4-stagefire. Every 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 Boards Figure 17 and 18, contain dipswitches which allow the user to control several system options. See Control System Section.

5

DIFFERENTIAL PRESSURE SWITCH

COMBUSTION AIR BLOWER

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, combustion and proper low NOx emission. 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.

The 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 vent system is clear. This pressure switch is normally closed and only opens on fault conditions.

FLAME SENSOR

The flame sensor detects the flame presence on burner's ports. 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. In the event of a lockout, depress the SELECT button on the UIM 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. It is a normally open switch that will close its contacts when increasing water flow rate is detected. The water flow switch is factory-set,but may require field adjustment. The contacts will open when the flow rate drops below the adjusted setting causing the gas valve(s) to close which will turn off the gas to the burners.

LIMIT CONTROLS

CAUTION

LIMIT CONTROLS ARE SAFETY DEVICES AND ARE NOT TO BE USED AS AN OPERATING CONTROL (THERMOSTAT).

The "G(B/W)" models incorporate an outlet water probe consisting of two limit controls:

1.An adjustable automatic reset limit control, that can be set as high as either 210°F (99°C) or 235°F (113°C) depending on the application.

2.A fixed manual reset limit (ECO) factory set at 244°F (118°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, push the SELECTION button on the UIM 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.

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 might require slight adjustment depending on site installation.

TANK PROBE

FOR HOT WATER SUPPLY SYSTEMS (GW models), a tank probe is supplied with each hot water supply boiler.

Note: The tank probe must be designated as the controlling probe using dip switch "4" on Central Control Board (Figure 17) 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 24VAC junction box. See Figure 12 for the tank probe installation. Follow the instructions in the "TANK PROBE INSTALLATION PROCEDURE". See page 18.

FOR HOT WATER HEATING SYSTEMS (GB models), a tank probe is not supplied with the GB models due to the many various types of systems and operating conditions. 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 applications. The tank probe connects to designated wires in the junction box at the rear of the boiler. Do not operate this boiler using the internal high limits only, use a tank probe or operating thermostat to control system temperatures.

Note: The tank probe or additional 24VAC devices must be identified using Dipswitches on Central Control Board before they are recognized as a part of the heating system; see Table 5. Refer to "Control System" section for more information about dipswitch settings.

CIRCULATING PUMP

The pump flow rate should not exceed the maximum recommended flow rate; see Table 5.

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 level 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; see page 16. 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.

6

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.

TOAVOID WATER DAMAGEADRAIN LINE MUST BE CONNECTED TOASAFETY RELIEF VALVE FOR DIRECT DISCHARGE TOASAFE LOCATION. A DRAIN LINE MUST NOT BE REDUCED FROM THE SIZE OF THE VALVE OUTLET AND IT MUST NOT CONTAIN ANY VALVES BETWEEN THE BOILER AND 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. INSTALLA 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 for Hot Water Supply Systems, ANSI Z21.22-CSA-4.4 (current edition). 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 on the water outlet header of the boiler.

FOR HOT WATER SUPPLY SYSTEMS, the boilers are shipped with a 125 psi pressure relief valve. This relief valve is factory installed on the water outlet header of the boiler. 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, a CSA design-certifiedandASME-ratedtemperature and pressure (T & P) relief valve must be installed on 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 OFALICENSED TRADESMAN IN THE FIELD INVOLVED. PLUMBING,AIR SUPPLY, VENTING, GAS SUPPLYAND ELECTRICAL WORK ARE REQUIRED.

LOCATION

When installing the boiler, consideration must be given to proper location. The 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. The 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.)

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 ADJACENTAREA 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. A hot water boiler installed above radiation level or as required by

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the authority having jurisdiction, must be provided with a low water cutoff device either as a part of the boiler or at the time of boiler installation.

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, 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 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) surrounding the 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 BASE KIT NUMBER

G(B,W) - 1000

211093

G(B,W) - 1300

211093-1

G(B,W) - 1500

211093-2

G(B,W) - 1850

211093-3

G(B,W) - 2100

211093-4

G(B,W) - 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 PROVIDED FOR PROPER COMBUSTION AND VENTILATION IN ACCORDANCE WITH THE NATIONAL FUEL GAS CODE, ANSI Z223.1 ORCAN/CSA-B149.1CURRENT EDITION ORAPPLICABLE 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 Btu/hr (22 cm2/k W) of the total input of all appliances in the enclosure.

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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 (5.5 cm2/kW) 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 (11 cm2/kW) 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 cross-sectionalarea shall be at least 10% of the area of the combustion air opening but in no case shall thecross-sectionalarea be less than 10 square inches (64.5 cm2).

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 (3.2 cm2/kW) up to and including 1,000,000 BTUHplus 1 square inch per 14,000 BTU (1.6 cm2/kW) 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

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.ANDAMAXIMUMDRAFTOF-0.04"W.C.MUSTBEMAINTAINED.IN INSTANCES OF EXCESSIVE DRAFT, ABAROMETRIC 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.

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.

STANDARD (VERTICAL) VENTING, CATEGORY I

THIS BOILER MAY BE VENTED ACCORDING TO TABLE 10 (ALSO

SEE FIGURE 6). AT LEAST TYPE B VENTING MUST BE USED WITH THE STANDARD VENTING OPTION (thru-the-roof)USING THE NATIONAL FUEL GAS CODE VENT TABLES. TYPE B VENT PIPECANNOT BE USED IF THE BOILER IS VENTED HORIZONTALLY OR AS A DIRECT VENT (SEE PAGES 12 THROUGH 15). ALL LOCAL UTILITY, STATE/ PROVINCIAL, REGULATIONS ON VENTING MUST BE FOLLOWED.

VENT SIZING, VENT CONNECTORS, INSTALLATION AND TERMINATION SHALL BE IN ACCORDANCE WITH THE CURRENT EDITION OF NATIONAL FUEL GAS CODE, ANSI Z223.1 OR CAN/CSA-B149.1or applicable provisions of the local building codes. Size and install proper size vent pipe; refer to Table 6.

Horizontal runs of vent pipe shall be securely supported by adequately placed (approximately every 4 feet [1.2 m]), noncombustible hangers suitable for the weight and design of the materials employed to prevent sagging and to maintain a minimum upward slope of 1/4" per foot (2 cm/m) from the boiler to the vent terminals. Dampers or other obstructions must not be installed in the vent. Be sure that the vent connector does not extend beyond the inside wall of the chimney.

TABLE 6: VENT CONNECTION

MODEL NUMBER

VENT CONNECTOR

G(B,W) 1000

10" (25.4 cm)

G(B,W) 1300

12" (30.5 cm)

G(B,W) 1500

12" (30.5 cm)

G(B,W) 1850

14" (35.6 cm)

G(B,W) 2100

14" (35.6 cm)

G(B,W) 2500

16" (40.6 cm)

For vent arrangements other than Table 10 and for proper boiler operation, a barometric damper is required to maintain draft between -0.02"W.C.. and-0.04"W.C. at 2 feet (0.6 m) above the boiler vent collar.

STANDARD (HORIZONTAL) VENTING, CATEGORYIII

Vent sizing, installation and termination shall be in accordance with the NATIONAL FUEL GAS CODE, ANSI Z223.1 ORCAN/CSA-B149.1(Current Editions). If applicable, all local, utility, state/provincial regulations on venting must be followed. See Table 11, Figure 7 for venting specifications. The exhaust vent pipe must be of a type listed for use with Category III gas burning heaters such as"Saf-T-Vent"manufactured byHeat-FabInc.

For Category III installations, it is important that the Installed vent be airtight. Please insure that all joints are sealed properly during installation. For Horizontal Vent Kit part numbers, see Table 7.

TABLE 7: HORIZONTAL VENT KITS.

HORIZONTAL VENT KIT

MODEL

211426

G(B,W) 1000

211426-1

G(B,W) 1300

 

211426-1

G(B,W) 1500

 

211426-2

G(B,W) 1850

 

211426-2

G(B,W) 2100

 

211426-3

G(B,W) 2500

 

DIRECT VENT VERTICALAND HORIZONTAL VENTING

For direct vent applications, this boiler may be vented according to Tables 12 and 13; see Figures 8 and 9. For category III applications,

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the exhaust vent pipe must be listed for use with category III gas burning heaters such as "Saf-T-Vent"manufactured byHeat-FabInc. This vent system must be 100% sealed with a condensate trap located as close to the boiler as possible. When sizing exhaust piping and intake air piping,90-degreeelbows are equivalent to 10 feet (3.1 m) of straight pipe and45-degreeelbows are equal to 5 feet (1.5 m) of straight pipe.

The intake air piping can be PVC, CPVC, ABS, Galvanized steel or any suitable intake air piping that can be sealed. See Table 8 for Direct Vent Kit numbers.

TABLE 8: DIRECT VENT KITS.

HORIZONTAL DIRECT VENT KIT NO.

MODEL

211090

G(B,W) 1000

211090-1

G(B,W) 1300

211090-1

G(B,W) 1500

211090-4

G(B,W) 1850

211090-2

G(B,W) 2100

211090-3

G(B,W) 2500

VERTICAL DIRECT VENT KIT NO.

MODEL

211089

G(B,W) 1000

211089-1

G(B,W) 1300

211089-1

G(B,W) 1500

211089-4

G(B,W) 1850

211089-2

G(B,W) 2100

211089-3

G(B,W) 2500

AIR INTAKE TERMINAL

MODEL

191965-2

G(B/W) 1000

211336

G(B/W) 1300,1500,1850

211336-1

G(B/W) 2100, 2500

HORIZONTAL VENT INSTALLATION

This boiler can be vented through the rear of the cabinet with the use of the fluebox and vent adaptor. Any of the previous venting configurations can be installed with rear connections.

To change the unit to rear exhaust:

1.The vent collar and cover plates must be removed from the top and rear of the unit.

2.Trim the insulation from around the rear flue hole in the jacket and the fluebox. Support insulation from inside the fluebox to facilitate cutting. Use safety precautions such as gloves. Place the gasket and vent adaptor in the horizontal position. Place the gasket and flue plate in the vertical position as shown in Figure 4.

Figure 4. Switching from Vertical to Horizontal Venting.

POWER VENT (OPTIONAL)

The length of vent used in horizontally vented installations can be extended beyond the lengths shown in Tables 11 and 13 by implementing the kits listed below:

TABLE 9: POWER VENT KITS.

POWER VENT KIT NO.

MODEL

MAX. LENGTH

211499

G(B,W) 1000

110' (33.5 m)

211499-1

G(B,W) 1300

100' (30.5 m)

211499-1

G(B,W) 1500

100' (30.5 m)

211499-2

G(B,W) 1850

100' (30.5 m)

211499-3

G(B,W) 2100

100' (30.5 m)

211499-4

G(B,W) 2500

100' (30.5 m)

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.

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.Insofar as is practical, close all building doors, windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.

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 the 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,

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