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COPPER BOILERS FOR
HYDRONIC HEATING AND
HOT WATER SUPPLY
• Installation
• Operation
• Maintenance
Instruction Manual
GB/GW MODELS:
1000, 1300, 1500, 1850, 2100, 2500
• 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.
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.
Thank You
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 P A G E
ROUGH-IN DIMENSIONS/CAPACITIES............. 2 - 3
FOREWORD .....................................................4 - 5
FEATURES/CONTROLS................................... 5 - 6
INSTALLA TION INSTRUCTIONS ................... 6 - 22
VENTING ....................................................... 8 - 14
SYSTEM INSTALLA TION ..............................15 - 19
HYDRONIC INST ALLATION ..........................15 - 17
HOT WA TER SUPPL Y INST ALLA TION ......... 17 - 19
GAS CONNECTIONS ....................................20 - 21
OPERATION ................................................ 22 - 23
LIGHTING AND OPERATING ......................... 24 - 25
CONTROL SYSTEM .................................... 26 - 31
PREVENTA TIVE MAINTENANCE ................ 31 - 33
TROUBLE SHOOTING ..................................33 - 34
LIMITED WARRANTY ..........................................35
WIRING DIAGRAM/SCHEMATIC .................. 36 - 37
for buying this cost
efficient, high recovery unit from
PLACE THESE INSTRUCTIONS ADJACENT TO BOILER AND
NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.
PRINTED IN U.S.A. 2526 0501
A DIVISION OF A. O. SMITH CORPORA TION
EL P ASO, TX., MC BEE, SC., RENTON, W A.,
STRATFORD-ONT ARIO, VELDHOVEN-THE NETHERLANDS
www.hotwater.com
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PART NO. 211257-000 REV . 0
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ROUGH-IN DIMENSIONS
TOP VIEW
FRONT VIEW
IMPORT ANT!
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
Manifold Pressure Electrical Characteristics
Model 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: 1 1.0 In. W.C. (2.74 kPa)
Minimum Pressures must be maintained under both load and no load
(static and dynamic) conditions.
Figure 1.
T ABLE 2. ROUGH - IN DIMENSIONS
ABCD EF
Model Inches c m Inches c m Inches cm Inches c m Inches cm Inches cm
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
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 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
BTU/Hr. KW BTU/Hr. KW Vent Diameter Vent Diameter Water Conn. Gas Inlet
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TABLE 3: RECOVERY CAP ACITIES
T emperature 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: HEA T 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 1 5 4 12.2 11 4 2 1.5 40
GB - 1300 109.2 7.2 72.8 4.2 54.6 3.2 1 5 4 14.5 1 4 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 1 5 4 18.5 2 0 78 6.4 4 0
GB - 2100 n/a n/a 117.6 14.5 88.2 8.3 154 21.3 23 8 9 8.3 40
GB - 2500 n/a n/a 139.4 18.5 104.6 11.6 154 23.2 2 8 105 11.6 4 0
Note: GW models (GB optional) are equipped with pumps capable of handling 50 equivalent feet
(15.2 m) of normal pipe fittings.
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FOREWORD
PRECAUTIONS
These designs comply with the latest edition of the American
National Standards for Gas-Fired, Low-Pressure Steam 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 inst alled 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
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/NFP A 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.
void if the boiler(s) have been improperly
GROUNDING INSTRUCTIONS
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 WA TER.
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 SITUA TION, 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.
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 OPERA TE 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 PREMA TURE DAMAGE, WHICH COULD
RESUL T IN SERIOUS PERSONAL INJUR Y OR DEATH.
FOR SYSTEMS THAT USE LARGE VOLUMES OF COLD WATER
OR SYSTEMS UTILIZING HEA VY WA TER DRAWS, CONDENSA TION
CAN BE PREVENTED BY USING A BYP ASS 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.
HIGH AL TITUDE INST ALLATION
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-REGULATING
PREJET ORIFICES WHICH AUT OMATICALL Y COMPENSATE FOR
HIGHER ELEVATIONS AND ADJUST THE APPLIANCE'S INPUT
RA TE ACCORDINGL Y, MAKING IT UNNECESSARY TO REPLACE
ORIFICES FOR HIGH ALTITUDE (UP TO 4,500 FEET ONLY.
CONSULT THE F ACTORY FOR HIGHER AL TITUDES.)
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.
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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
FLAME SENSOR
The flame sensor acts to prove the flame has carried over from the
ignitor to the right-most burner. 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 rest art the boiler.
MUL TI-STAGE FIRING 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 a
multi-stage control 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 CONFIGURA TION T ABLE
SW 1 OFF ON SELECTION:
A 3 STAGE 4 STAGE EITHER 3 OR 4 STAGE SYSTEM
B 3 TRIALS 1 TRIAL EITHER 3 OR 1
C NO IRI IR I WHETHER SYSTEM IS IRI OR
GAS VALVE GAS VALVE STANDARD
D INLET T ANK INLET OR T ANK AS
CONTROLLING PROBE
E NO EXTERNAL EXTERNAL WHETHER EXTERNAL
THERMOSTAT THERMOSTAT THERMOSTA T IS USED
F OUTLET 210°F OUTLET 240°F OUTLET MAXIMUM TEMPERA TURE
G 190°F 220°F MAX. SET-POINT TEMPERA TURE
H DEGREES °F DEGREES °C EITHER °F OR °C FOR DISPLAYED
TEMPERA TURE
WA TER 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 THERMOST AT .
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-button on the display panel to restart the boiler.
ON/OFF SWITCH
The ON/OFF switch is a single-pole, single-throw rocker switch.
The switch provides 120VAC from the line source to the boiler.
COMBUSTION AIR BLOWER
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-mix chamber 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 the pre-mix
chamber. 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.
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.
T ANK PROBE
FOR HOT WA TER SUPPL Y 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-supplied wires 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
many various types of systems and operating conditions, a tank
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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-Stage Firing and Control System" on previous page for more
information about dip switch settings.
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 (HEA TING 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-off Devices for Hot Water
Supply Systems, ANSI Z21.22 or CSA-4.4 (and latest addendums).
The valve must be of the automatic reset type and not embody a
single-use type fusible plug, cartridge or linkage.
CIRCULA TING PUMP
The pump flow rate should not exceed the maximum
recommended flow rate, see table 4.
FOR HOT WA TER 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 WA TER HEA TING SYSTEMS (GB models or GW models
ordered without circulator), the circulator is NOT provided and
must be field-installed.
LOW WA TER CUT OFF (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 V AL VE (Not Supplied)
Additional drain valves must be obtained and installed on each
boiler and tank for draining purposes.
SAFETY RELIEF V AL VES
Your local code authority may have other specific relief valve
requirements not covered below.
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-rated valve 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-certified and ASME-rated temperature
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.
WARNING
THE PURPOSE OF A SAFETY RELIEF VALVE IS TO AVOID
EXCESSIVE PRESSURE WHICH MAY CAUSE T ANK EXPLOSION,
SYSTEM OR BOILER DAMAGE.
TO A VOID W A TER DAMAGE A DRAIN LINE MUST BE CONNECTED
TO A SAFETY RELIEF VAL VE 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
V ALVES BETWEEN THE BOILER AND THE RELIEF V AL VE 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. INST ALL A DRAIN LINE WITH
A DOWNWARD SLOPE SUCH THAT IT NATURALLY DRAINS
ITSELF.
INST ALLA TION INSTRUCTIONS
REQUIRED ABILITY
INST ALLATION OR SER VICE OF THIS BOILER REQUIRES ABILITY
EQUIVALENT TO THAT OF A LICENSED TRADESMAN IN THE
FIELD INVOLVED. PLUMBING, AIR SUPPLY, VENTING, GAS
SUPPL Y AND ELECTRICAL WORK ARE REQUIRED.
LOCA TION
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 INST ALLED ON CARPETING.
• THE BOILER SHOULD NOT BE LOCA TED IN AN AREA WHERE
IT WILL BE SUBJECT TO FREEZING.
• THE BOILER SHOULD BE LOCA TED 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 T O LOWER
FLOORS OF THE STRUCTURE.
WHEN SUCH LOCATIONS CANNOT BE AVOIDED, A SUITABLE
DRAIN PAN SHOULD BE INST ALLED 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, OPERA TED OR REP AIRED. 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 OPERA TION OF GAS
APPLIANCES IF INSTALLED 18 INCHES (46.0 CM) OR MORE
ABOVE THE FLOOR. THIS MA Y REDUCE THE RISK IF LOCA TION
IN SUCH AN AREA CANNOT BE A VOIDED.
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.
INST ALLATION 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.
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 CIRCUMST ANCES SHOULD THE EQUIPMENT ROOM
WHERE THE BOILER IS INSTALLED EVER BE UNDER NEGA TIVE
PRESSURE. PARTICULAR CARE MUST BE TAKEN WHEN
EXHAUST FANS, COMPRESSORS, AIR HANDLING EQUIPMENT,
ETC., MAY INTERFERE WITH THE COMBUSTION AND
VENTILA TION AIR SUPPLIES OF THIS BOILER.
CHEMICAL V APOR 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.
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
7
Page 8
PROVIDED FOR PROPER COMBUSTION AND VENTILATION IN
ACCORDANCE WITH
Z223.1 OR CAN/CSA-B149.1 AND .2 (LATEST EDITIONS) OR
APPLICABLE PROVISIONS OF THE LOCAL BUILDING CODES.
AN INSUFFICIENT SUPPL Y 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.
THE NATIONAL FUEL GAS CODE, ANSI
UNCONFINED SP ACE
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 OF ASPHYXIA TION.
VENTING
!
This boiler is approved to be vented as a Category I, Category III
(horizontal venting), or a Direct V ent appliance. The Horizont al and
Direct Venting options require a special vent kit.
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 SP ACE
(a) U. S. INST ALLATIONS
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 INSTALLA TIONS
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- sectional area shall
be at least 10% of the area of the combustion air opening but in no
case shall the cross-sectional area be less than 10 square inches
(6500 mm
In addition to the above, there shall be permanent air supply
opening(s) having a cross-sectional area of not less than 1 square
inch per 7,000 BTUH (310 mm
BTUH
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,
2
).
2
/KW) up to and including 1,000,000
plus 1 square inch per 14,000 BTU in excess of 1,000,000
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 V ent 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 OPERA TION, A MINIMUM DRAFT OF -0.02"
W.C. AND A MAXIMUM DRAFT OF -0.04" W .C. MUST BE MAINT AINED.
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 ASPHYXIA TION.
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-1 gas 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 step s 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.
8
Page 9
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 or CAN/CSA-B149.1 and .2
(and latest addendums), or applicable provisions of the local
building codes.
LOCATION REQUIREMENTS (INT AKE/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.
Direct venting into dead air spaces such as alleys, atriums and
CAUTION
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. T o 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 T ermination Inst allation Clearances
9
Page 10
STANDARD VENT - VERTICAL (CATEGORY I)
IMPORT ANT!
VENT PRESSURE MUST BE MAINT AINED
BETWEEN -0.02" W.C. AND -0.04" W.C. AT 24"
(61.0 cm) ABOVE BOILER COLLAR.
Figure 5.
T ABLE 7. ST ANDARD VERTICAL VENTING (CA TEGORY I)
APPLIANCE CERTIFIED EXHAUST MAXIMUM LENGTH WITHOUT
MODEL CA TEGOR Y VENTING VENT SIZE BAROMETRIC DAMPER (FEET)
MA TERIAL (INCHES)
I000
1300 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 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
* 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-B149.1
and .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.
I
I
I
I
TYPE B OR 10”(25.4 cm) 35 Feet (10.7 m) without damper
EQUIV ALENT *70 Feet (21.3 m) max. with damper
TYPE B OR 16" (40.6 cm) 35 Feet (10.7 m) without damper
EQUIV ALENT *70 Feet (21.3 m) max. with damper
10
Page 11
STANDARD VENT - HORIZONTAL (CATEGORY III)
Figure 6.
T ABLE 8. ST ANDARD HORIZONT AL VENTING (CA TEGORY III)
APPLIANCE CERTIFIED EXHAUST MAXIMUM
MODEL CA TEGOR Y VENTING VENT SIZE VENT LENGTH
MA TERIAL (INCHES) (FEET)
I000
1300 STAINLESS
1500 STEEL
1850 STAINLESS
2100 STEEL
2500
WARNING: No substitutions of flue pipe or vent cap material are allowed. Such substitutions would jeopardize the
safety and health of inhabitants.
• A maximum of two elbows can be used on inlet and outlet vent piping respectively. Each elbow is equal to 10 feet (3 m) of
straight pipe.
III
III
III
III
ST AINLESS
STEEL
ST AINLESS
STEEL
10”(25.4 cm)
12" (30.5 cm)
14"(35.6 cm)
16" (40.6 cm)
70' (21.3 m)
70' (21.3 m)
70' (21.3 m)
70' (21.3 m)
• Use only special 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 WPC, 5621 W. 115th Street, Alsip, IL 60803 Phone: 1-800-433-2545 or
Fax: 1-800-433-2515. Pipe joints must be positively sealed.
11
Page 12
DIRECT VENT - VERTICAL (CATEGORY I)
Figure 7.
T ABLE 9. DIRECT VENT (VERTICAL EXHAUST CONFIGURA TIONS)
APPLIANCE CERTIFIED EXHAUST VENT MAXIMUM AIR INT AK E AIR INLET MAXIMUM
MODEL CATEGOR Y EXHAUST VENT SIZE (INCHES) EXHAUST VENT MA TERIAL SIZE (INCHES) AIR INT AKE
MATERIAL LENGTH (FEET) LENGTH (FEET)
GAL. STEEL
CPVC
GAL.STEEL
CPVC
GAL. STEEL
CPVC
GAL. STEEL
CPVC
GAL. STEEL
CPVC
8"
(20.3 cm)
10"
(25.4 cm)
10"
(25.4 cm)
12"
(30.5 cm)
12"
(30.5 cm)
I000
1300
1500
1850
2100
2500
I PVC, ABS OR
I PVC, ABS CR
I PVC, ABS OR
I PVC, ABS OR
I PVC, ABS OR
TYPE B OR
EQUIV ALENT
TYPE B OR
EQUIV ALENT
TYPE B OR
EQUIV ALENT
TYPE B OR
EQUIVALENT
TYPE B OR
EQUIV ALENT
10"
(25.4 cm)
12"
(30.5 cm)
14"
(35.6 cm)
14"
(35.6 cm)
16"
(40.6 cm)
35'
(10.7 m)
35'
(10.7 m)
20'
(6.1 m)
20'
(6.1 m)
20'
(6.1 m)
35'
(10.7 m)
35'
(10.7 m)
20'
(6.1 m)
20'
(6.1 m)
20'
(6.1 m)
• 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-B149.1
and .2 Installation Code (Canada).
• The vent should be installed so as to prevent the accumulation of condensate and, where necessary , have means provided for
drainage of condensate. 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.
12
Page 13
DIRECT VENT - HORIZONTAL (CATEGORY III)
Figure 8.
T ABLE 10. DIRECT VENT (HORIZONT AL EXHAUST CONFIGURA TIONS)
APPLIANCE CERTIFIED VENT MAXIMUM AIR INT AK E AIR INLET MAXIMUM
MODEL CATEGOR Y EXHAUST VENT SIZE VENT LENGTH MATERIAL SIZE AIR INTAKE
MATERIAL (INCHES) (FEET) (INCHES) LENGTH (FEET)
GAL. STEEL
CPVC
GAL.STEEL
CPVC
GAL. STEEL
CPVC
GAL. STEEL
CPVC
GAL. STEEL
CPVC
8"
(20.3 cm)
10"
(25.4 cm)
10"
(25.4 cm)
12"
(30.5 cm)
12"
(30.5 cm)
I000
1300
1500
1850
2100
2500
III PVC, ABS OR
III PVC, ABS CR
III PVC, ABS OR
III PVC, ABS OR
III PVC, ABS OR
STAINLESS
(SEALED)
STAINLESS
(SEALED)
STAINLESS
(SEALED)
STAINLESS
(SEALED)
STAINLESS
(SEALED)
10"
(25.4 cm)
12"
(30.5 cm)
14"
(35.6 cm)
14"
(35.6 cm)
16"
(40.6 cm)
35'
(10.7 m)
35'
(10.7 m)
20'
(6.1 m)
20'
(6.1 m)
20'
(6.1 m)
35'
(10.7 m)
35'
(10.7 m)
20'
(6.1 m)
20'
(6.1 m)
20'
(6.1 m)
WARNING: No substitutions of flue pipe or vent cap material are allowed. Such substitutions would jeopardize the
safety and health of inhabitants.
• A maximum of two elbows can be used on inlet and outlet vent piping respectively. Each elbow is equal to 10 feet (3 m) of
straight pipe.
• Use only special gas vent pipes listed for use with Category III gas burning heaters, such as stainless steel Saf-T -Vent by Heat
Fab, Inc. Inc., available from A.O. Smith WPC, 5621 W. 115th Street, Alsip, IL 60803 Phone: 1-800-433-2545 or
Fax: 1-800-433-2515. Pipe joints must be positively sealed.
13
Page 14
STANDARD (VERTICAL) VENTING, CATEGOR Y I
STANDARD (HORIZONT AL) VENTING , CA TEGORY III
THIS BOILER MAY BE VENTED ACCORDING T O T ABLE 7 (ALSO
SEE FIGURE 5). AT LEAST TYPE B VENTING MUST BE USED
WITH THE STANDARD VENTING OPTION (thru-the-roof) USING
THE NATIONAL FUEL GAS CODE VENT T ABLES.* TYPE B VENT
CANNOT BE USED IF THE BOILER IS VENTED
PIPE
HORIZONTALLY OR AS A DIRECT VENT (SEE PAGES 11
THROUGH 13). ALL LOCAL UTILITY, STATE/ PROVINCIAL,
REGULATIONS ON VENTING MUST BE FOLLOWED.
VENT SIZING, INSTALLATION AND TERMINATION SHALL BE IN
ACCORDANCE WITH THE
Z223.1 OR CAN/CSA-B149.1 and .2 (AND LATEST ADDENDA).*
Vent connections must be made to an adequate stack or chimney
and shall be in accordance with the
Z223.1 or CAN/CSA-B149.1and .2 (and latest addenda) or
applicable provisions of the local building codes. Size and install
proper size vent pipe.
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 1 1: VENT CONNECTION
VENT CONNECTOR MODEL NUMBER
G(W,B) 1000 10" (25.4 cm)
G(W,B) 1300 12" (30.5 cm)
G(W,B) 1500 12" (30.5 cm)
G(W,B) 1850 14" (35.6 cm)
G(W,B) 2100 14" (35.6 cm)
G(W,B) 2500 16" (40.6 cm)
For vent arrangements other than table 7 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.
NATIONAL FUEL GAS CODE, ANSI
National Fuel Gas Code, ANSI
Vent sizing, installation and termination shall be in accordance
with the
CAN/CSA-B149.1 AND .2 (LATEST EDITIONS). If applicable, all
local, utility , state/provincial regulations on venting must be followed.
See table 8 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 by Heat-Fab Inc.
For Category III installations, It is important that the Installed vent
be airtight. Please insure that all joints are sealed properly during
installation.
For direct vent applications this boiler may be vented according to
tables 9 and 10. For category III applications, the exhaust vent pipe
must be special gas vent pipe listed for use with category III gas
burning heaters such as "Saf-T-Vent" manufactured by Heat-Fab
Inc. 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-degree elbows
are equivalent to 10 feet (3.1 m) of straight pipe and 45-degree
elbows are equal to 5 feet (1.5 m) of straight pipe.
The intake air piping can be PVC, CPVC, ABS or any suitable intake
air piping that can be sealed.
Combustion air from outside the building ducted to boiler air inlet
(Ducted Air Application) cannot be used in rooms with negative
pressure.
NATIONAL FUEL GAS CODE, ANSI Z223.1 OR
DIRECT VENT VERTICAL AND HORIZONT AL VENTING
HORIZONTAL VENT INST ALLATION
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 9.
Figure 9. Switching from Vertical to Horizont al V enting
14
Page 15
SYSTEM INST ALLA TION
CONVENTIONAL SP ACE HEATING INST ALLA TION
GENERAL
If the system is to be filled with water for testing or other purposes
during cold weather and before actual operation, care must be
taken to prevent a down draft entering the boiler or freezing air from
contacting the system. Failure to do so may cause the water in the
system to freeze with resulting damage to the system. Damage
due to freezing is not covered by the warranty.
Good practice requires that all piping, etc., be properly supported.
The boilers described in this manual may be used for space
(hydronic) heating or for the heating of potable water. If the heater
is to be used for hydronic space heating, follow the instructions on
pages 15-17 given for equipment required for installation as in
Figure 10. However, if units are to be used for heating potable
water, the information describing specific systems is found on
pages 17-19. See figures 11 and 13. Installations must comply
with all local codes.
HYDRONIC INST ALLATION
The following is a brief description of the equipment required for
installations noted in this manual. All installations must comply
with local codes (see figure 10).
Table 12: INST ALLA TION ITEMS
NO. SUGGESTED ITEMS FOR INST ALLATION
1. PAIR OF SHORT PIPE NIPPLES, P AIR OF BOILER
LOOP TEES AND BALL V AL VE BETWEEN SYSTEM
SUPPLY AND RETURN - ONE SET PER EACH BOILER
2. BOILER PIPE LOOP (See Sizing Data Table 4.)
3. BOILER CIRCULATING PUMP (See Sizing Data Table 4.)
4. THERMOMETER
5. PRESSURE GAUGE
6. LOW WATER CUTOFF (If Required By Local Code.)
7. SAFETY FLOW SWITCH (Factory-Installed)
8. RELIEF VALVE (Factory-Installed)
9. BOILER INLET - OUTLET
10. SYSTEM SUPPLY TEMPERA TURE THERMOMETER
11. DRAIN or BLOW-DOWN V AL VE
WA TER SUPPL Y LINE
These boilers can be used ONLY in a forced circulation hot water
heating system. The pump must be interlocked with the boiler to
prevent boiler operation without water circulation. See maximum
and minimum flow rate information. Since most forced circulation
systems will be of the closed type, install the water supply line as
shown on piping diagram, figure 10. Severe damage will occur if
the boiler is operated without proper water flow circulation.
Modern fin type boilers are exceptionally fast heating units. The low
water volumes in relation to firing rates require special attention to
water flow rates for smooth, efficient operation. These
considerations for the A. O. Smith copper heat exchanger boilers
are covered below.
Refer to table 4 showing flow rate vs. pressure drop and temperature
rise.
Figure 10 shows a typical installation of the boiler.
A system with several flow controlled zones, or with a 3-way mixing
valve system could present a flow rate to the boiler of less than
required for a maximum of 50°F (28°C) temperature rise. Design
system with compensating bypasses to the boiler.
A system bypass should be installed as shown in figure 10 to
prevent boiler circulation starvation when the system zones call for
reduced flow.
This bypass may also be used with multiple 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
heating coils located in air handling units where they may be
exposed to circulating refrigerated air, must be equipped with flow
control valves or other automatic means to prevent gravity circulation
of the boiler water during the cooling cycle. It is highly recommended
that the piping be insulated.
INST ALLATION AS BOILER REPLACEMENT
Installation as boiler replacement on an old system with large water
volume may result in 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 increase in boiler temperature rise.
BYPASS BALANCING
With systems where water temperature can be expected to drop
appreciably due to long standby periods, or heavy draw down, a
bypass pipe of at least 1" size with a balancing cock should be
installed between the boiler inlet and outlet (see figure 10). When
the system first starts, the valve should be slowly opened until the
condensing ceases. This adjustment remains at a permanent
setting to establish required temperature rise across the boiler.
AIR SEPARA TOR
An air separator as shown in the piping diagram is reccommended
especially for modern commercial hydronic systems.
Fast filling of large pipe, old radiator installations (where high
pressures are not available) requires bypassing of the pressure
reducing valve. Generally, pressure purging is not possible with a
well pump system. High point air venting is essential. For details,
refer to OPERATION section of this manual on page 22.
If the system is of the open type, a pressure reducing valve will not
be required as the water supply to the system will be controlled by
a manually operated valve. An overhead surge tank is required.
MINIMUM PRESSURE OF 15 PSI (100 kPa) MUST BE MAINT AINED
ON THE BOILER AT ALL TIMES to avoid potential damage to the
boiler that may not be covered by the warranty.
VENT V AL VES
It is recommended that automatic, loose key or screwdriver type
vent valves be installed at each convector or radiator.
SYSTEM HEADERS
Split systems with individual supply and return lines from the boiler
room should normally have this piping connected to supply and
A
return manifold headers near the boiler. To achieve good water
distribution with minimum pressure drop for several circuits,
manifolds should be larger than system loops.
15
Page 16
The circuits should be spaced on the header at a minimum of
3" (7.6 cm) center to center. Install a balancing cock in each return
line.
Manifold headers are recommended for split systems with or
without zone valves and also those installations with zone
circulators. If the system is to be split at remote points, good practice
requires special attention be given to main pipe sizing to allow
balancing of water flow.
COOLING PIPING
When the boiler is used in conjunction with a refrigeration system
it must be installed so that the chilled medium is piped in parallel
with the boiler. Appropriate valves, manual or motorized, must be
provided to prevent the chilled medium from entering the boiler.
Water temperature in the heating system must be reduced to less
than 100°F before cooling system is started, or damage to the
chiller unit may occur.
If the boiler is connected to chilled water piping or heating coils
exposed to refrigerated air, the boiler piping system must be
equipped with flow control valves or other automatic means to
prevent gravity circulation through the boiler during the cooling cycle.
Primary/secondary pumping of both the chiller(s) and the boiler(s)
is an excellent winter-summer change-over method, because
cooling flow rates are much more than heating flow rates. In this
way each system (heating or cooling) is circulated independently.
SP ACE HEATING APPLICATIONS
installation might be controlled directly from space temperature
thermostat(s). Multiple boiler installations are more effective when
the boilers are sequenced in and out of operation by some form of
main water temperature controller. With one or two boilers, individual
control settings at progressive temperature may be used. For more
than two boilers, electronic sequencing controlling is
recommended.
Individual controls, or the separate stages of a step controller,
should fire a boiler and also start the boiler loop circulator whenever
that boiler is fired. Some large installations may require the firing
of more than one boiler per stage.
The system or primary circulator may or may not be controlled by
the boiler sequencer. When this pump is operated through the first
switch of any type of step controller, care should be taken to
determine if a motor starter is needed due to insufficient switch
capacity.
If the primary pump is controlled by a manual switch or any other
controllers, the electric current supply to the boiler group should be
through the primary pump controller. The fast response of
A.O. Smith boilers eliminates any need to maintain boiler
temperature when the system is satisfied. Wiring should always
prevent firing of boiler(s) when there is no water flow in the
mains.
Installation diagrams show safety flow switches in the outlet piping
from each boiler as good protection against any boiler being fired
when the boiler loop circulator is not in operation. These safety flow
switches will also provide some protection if there is a loss of water.
Controlling of these systems is decided mainly by the type of
building system controlling that is desired. A single boiler
Multiple boiler installations are especially adapted to the use of
outdoor reset for main water temperatures. This feature is not
Figure 10. Single or Multiple Boiler Installation Diagram
16
Page 17
mandatory but offers smooth, efficient operation of a modern
system.
Normal use of flow control valves is required to prevent cross
circulation of zones as with any multiple pump system.
Large systems with multiple boilers should include main water
temperature controls (with or without outdoor reset) to sequence
the boiler on and off, in relation to the load on the system.
24 V AC System Controller (Optional)
GB models require a field supplied 24VAC operating control to be
installed in the system such as: loop thermostat, indoor/outdoor
reset control, sequencing panel, or energy management system.
The connection for such devices is located in the 24 VAC junction
box at the rear of the unit. A 24 VAC thermost at/aquast at can only be
used as an "On/Off" switch for the unit. The actual controlling of the
staging will be through either the inlet or tank probe. To use a 24 VAC
system controller, dip switch "E" on the CCB must be switched to the
"on" position. See figure 14.
INTERNAL CONT AMINANTS
HARD WA TER CONDITIONS
Where hard water conditions exist, water softening or the threshold
type of water treatment is recommended. This will protect the
dishwashers, coffee urns, water heaters, water piping and other
equipment. When water softening or water treatment is not practical,
a comparatively easy method of periodic lime removal from the unit
must be employed.
WARNING
LIME ACCUMULATION CAN REDUCE THE LIFE OF THE
EQUIPMENT , REDUCE EFFICIENCY AND WASTE FUEL. BOILER
FAILURE DUE TO LIME OR SCALE BUILDUP VOIDS THE
WARRANTY.
Tank Probe (Optional)
In addition to the Inlet and Outlet/ECO Probes, units can be
optionally equipped with a tank Probe. The connection for the tank
probe is located in the 24VAC junction box at the rear of the unit.
The tank Probe can be configured to control the staging of the unit.
See Tank Probe Installation section below for additional
information.
The system must be internally cleaned and flushed after a new or
replacement unit has been installed to remove contaminants that
may have accumulated during installation. This is doubly important
when a replacement unit is installed into an existing system where
Stop Leak or other boiler additives have been used.
All systems should be completely flushed with a grease removing
solution to assure trouble-free operation. Pipe joint compounds,
soldering paste, grease on tubing and pipe all tend to contaminate
a system.
Failure to clean and flush the system can cause solids to form on
the inside of the heat exchanger, can produce acid concentrations
that become corrosive, can allow excessive amounts of air or other
gases to form which could block circulation, foul system
accessories and damage circulator seals and impellers.
It is recommended that after installation, the boiler and system
when filled should include the proper percentage of cleaning
solution related to approximate water volume of the system. Fire
and circulate for about one hour and then flush clean with fresh
water. Commercial grease removing solutions are available.
Before operating the boiler, the entire system must be filled with
water, purged of air and checked for leaks. Do not use S top Leak or
other boiler compounds. The gas piping must also be leak tested.
THE WA TER HEA TER SHOULD BE LOCA TED IN AN AREA WHERE
THE GENERAL PUBLIC DOES NOT HAVE ACCESS TO SET
TEMPERA TURES.
HOT WATER SUPPLY BOILER
T ANK PROBE INSTALLA TION PROCEDURE
A tank probe is supplied with each hot water supply boiler (GW). To
connect the tank probe to the boiler, remove the cover from the 24
VAC junction box at the rear of the unit. Connect the probe wires
across terminals 1 & 2. (The wires leading to the terminals will be
yellow.) Check the field connection diagram located on this cover
of the junction box to assure proper wiring.
Once the tank probe has been connected to the boiler, it must be
designated as the controlling probe for the system. This is
accomplished by changing two Dip Switch settings on the Central
Control Board. First, Dip Switch "D" must be set to the "ON" position
to designate the tank probe as the controlling probe. Second, Dip
Switch "G" must be set to the "OFF" position to limit the maximum
tank probe temperature for GW applications. It is also advisable to
make sure Dip Switch "F" is set to the "OFF" position which sets the
Outlet temperature Set-Point to 210°F (99°C). See figure 14. Failure
to do this will void the warranty. If the tank probe is not designated
as the controlling probe, the staging of the unit will be controlled by
the Inlet Probe and will not use the desired tank temperature as its
base. Once the tank Probe is designated as the controlling probe,
the Inlet Water Temperature on the display will default to the tank
temperature.
Refer to "Connection Diagram" (figure 20) and figure 12 in order to
connect the tank probe to the boiler.
See section titled "PROCEDURES FOR SETTING TANK PROBE
TEMPERATURE", following the Lighting Instructions for instructions
on how to set the temperature.
INSTALLATION
WA TER LINE CONNECTIONS
Where excessive heat exchanger condensation exists due to
continued low inlet water temperatures (below 120
balance loop must be installed (see figures 11 and 13).
o
F), a bypass
EXPANSION T ANK
If the system is of the closed type, install an expansion tank as
shown in figures 11 and 13. The sizing of the expansion tank for a
closed system is very important and is directly related to the total
water volume of the system. Refer to ASME or other reliable
specifications for sizing.
17
Page 18
ONE GENESIS (MODEL GW) HOT WATER SUPPLY BOILER WITH HORIZONTAL TANK
INSTAL L THERMAL EXPANSION
TANK ON COLD WATER
SUPPLY LINE, IF CHECK VALVE
OR PRESSURE REDUCING
VALVE IS USED IN SUPPLY.
DANGER
TEMPERATURE SETTING SHOULD NOT EXCEED
SAFE USE TEMPERATURE AT FIXTURES.
SEE WATER TEMPERATURE CONTROL
WARNING ON P AGE 23. IF HIGHER PREHEA T
TEMPERA TURES ARE NECESSARY TO OBTAIN
ADEQUATE BOOSTER OUTPUT, ADD AN
ANTI-SCALD VALVE FOR HOT WATER
SUPPLIED TO FIXTURES.
PRESSURE RELIEF VALVE RATING SHOULD
NOT EXCEED PRESSURE CAPACITY OF ANY
COMPONENT IN THE SYSTEM.
PIPING SHOULD CONFORM TO LOCAL CODES.
BALL VALVES ARE SHOWN FOR SERVICING
BOILER. HOWEVER, LOCAL CODES SHALL
GOVERN THEIR USAGE.
IMPORTANT
SAFETY 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
THE WA TER MANIFOLD IS NOT DESIGNED T O
WARNING
SUPPORT THE WEIGHT OF THE WA TER PIPING
SYSTEM. AS ON ALL BOILER INST ALLA TIONS,
SPECIAL CARE MUST BE T AKEN T O ENSURE
PROPER SUPPORT .
TWO TEMPERATURE W A TER
MIXING VALVE APPLICATION
CIRCULATING RETURN
LINE CONNECTIONS
• TEMPERED WATER LOOP, IF USED,
CONNECT TO POINT R.
• STORED TEMPERATURE WA TER LOOP ,
IF USED, CONNECT TO ANY OPENING
NEAR BOTTOM OF T ANK.
MINIMUM
MODELS
MODELS INCHES
GW-1000
THRU 2 1/2"
2500 NPT
FACTORY PUMP SIZING
BASED ON 50 EQUIVALENT
FEET (15.2 m) OF PIPE.
PIPE SIZE
Figure 11. Single boiler with horizont al tank.
Encase field-supplied wires
between tank probe and junction
box with 1/2" field supplied
conduit. "Pigtails" of fieldsupplied wires should be spliced
to "pigtails" of tank probe and
connected to 24 VAC junction box
(see figure 20). This conduit and
wiring should be separate from
any other conduit/wiring to guard
against EMI (electromagnetic
interference).
Figure 12. T ank probe installation.
18
Page 19
ONE GENESIS (MODEL GW) HOT WATER SUPPLY BOILER WITH VERTICAL TANK
PRESSURE RELIEF VALVE RATING SHOULD NOT EXCEED PRESSURE CAPACITY OF ANY COMPONENT IN THE SYSTEM.
PIPING SHOULD CONFORM TO LOCAL CODES.
BALL VALVES ARE SHOWN FOR SERVICING BOILER. HOWEVER, LOCAL CODES SHALL GOVERN THEIR USAGE.
IMPORTANT
SAFETY 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 EXPANSION
TANK ON COLD WATER SUPPLY
LINE, IF CHECK VALVE OR
PRESSURE REDUCING VALVE
IS USED IN SUPPLY.
Figure 13. Single boiler with vertical tank.
MINIMUM
MODELS
PIPE SIZE
MODELS INCHES
GW-1000
THRU 2 1/2"
2500 NPT
FACTORY PUMP SIZING BASED
ON 50 EQUIVALENT FEET
(15.2 m) OF PIPE.
19
DANGER
TEMPERATURE SETTING SHOULD NOT EXCEED SAFE USE
TEMPERATURE A T FIXTURES. SEE W A TER TEMPERA TURE
CONTROL WARNING ON P AGE 23. IF HIGHER PREHEA T TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE
BOOSTER OUTPUT, ADD AN ANTI-SCALD VAL VE FOR HOT
WA TER SUPPLIED TO FIXTURES.
TWO TEMPERATURE W A TER
MIXING VALVE APPLICATION
CIRCULATING RETURN
LINE CONNECTIONS
• TEMPERED WATER LOOP, IF USED,
CONNECT TO POINT R.
• STORED TEMPERATURE WA TER LOOP ,
IF USED, CONNECT TO ANY OPENING
NEAR BOTTOM OF T ANK.
Page 20
4" BTU/hr 35,880,000 24,648,000 19,968,000 17,004,000 15,132,000 13,728,000 12,636,000 11,700,000 11,232,000 10,452,000 9,360,000 8,580,000 7,800,000 7,176,000
kW 10,508 7,219 5,848 4,980 4,432 4,021 3,701 3,427 3,290 3,061 2,741 2,513 2,284 2,102
3" BTU/hr 17,160,000 12,012,000 9,750,000 8,268,000 7,410,000 6,708,000 6,084,000 5,772,000 5,382,000 5,070,000 4,602,000 4,134,000 3,822,000 3,556,800
kW 5,026 3,518 2,856 2,421 2,170 1,965 1,782 1,690 1,576 1,485 1,348 1,21 1 1,1 19 1,042
kW 2,878 1,987 1,608 1,371 1,211 1,097 1,028 937 891 845 754 685 626 585
2 1/2" BTU/hr 9,828,000 6,786,000 5,491,200 4,680,000 4,134,000 3,744,000 3,510,000 3,198,000 3,042,000 2,886,000 2,574,000 2,340,000 2,137,200 1,999,800
kW 1,805 1,256 1,005 868 768 694 64 0 594 557 525 466 434 388 366
1 1/2" BTU/hr 3,276,000 2,277,600 1,840,800 1,544,400 1,404,000 1,263,600 1,170,000 1,076,400 1,014,000 - - - - - - - - - - - - - - -
2" BTU/hr 6,162,000 4,290,000 3,432,000 2,964,000 2,620,800 2,371,200 2,184,000 2,028,000 1,903,200 1,794,000 1,591,200 1,482,000 1,326,000 1,248,000
kW 959 667 539 452 411 370 343 315 297 - - - - - - - - - - - - - - -
kW 640 434 352 302 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
kW 410 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
1 1/4" BTU/hr 1,400,000 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
(Inches) (3.05) (6.10) (9.14) (12.19) (15.24) (18.29) (21.34) (24.38) (27.43) (30.48) (38.10) (45.72) (53.34) (60.96)
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 Ft. 200 Ft.
Iron Pipe
Nominal
T able 13. Suggested Pipe Size For Multiple Gas Appliances (Natural)
(Inches) (3.05) (6.10) (9.14) (12.19) (15.24) (18.29) (21.34) (24.38) (27.43) (30.48) (38.10) (45.72) (53.34) (60.96)
Iron Pipe
1 1/4" BTU/hr 2,184,000 1,482,000 1,201,200 1,029,600 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
1" BTU/hr 1,060,800 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
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 Ft. 200 Ft.
Nominal
kW 311 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Table 14. Suggested Pipe Size For Multiple Gas Appliances (Propane Gas)
4" BTU/hr 23,000,000 15,800,000 12,800,000 10,900,000 9,700,000 8,800,000 8,100,000 7,500,000 7,200,000 6,700,000 6,000,000 5,500,000 5,000,000 4,600,000
kW 6,736 4,627 3,749 3,192 2,841 2,577 2,372 2,197 2,109 1,962 1,757 1,611 1,464 1,347
kW 3,222 2,255 1,830 1,552 1,391 1,259 1,142 1,084 1,010 952 864 776 718 668
3" BTU/hr 11,000,000 7,700,000 6,250,000 5,300,000 4,750,000 4,300,000 3,900,000 3,700,000 3,450,000 3,250,000 2,950,000 2,650,000 2,450,000 2,280,000
kW 1,845 1,274 1,031 879 776 703 659 600 571 542 483 4 39 401 375
2 1/2" BTU/hr 6,300,000 4,350,000 3,520,000 3,000,000 2,650,000 2,400,000 2,250,000 2,050,000 1,950,000 1,850,000 1,650,000 1,500,000 1,370,000 1,280,000
kW 1,157 805 644 556 492 445 410 381 357 337 299 - - - - - - - - -
1 1/2" BTU/hr 2,100,000 1,460,000 1,180,000 990,000 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
2" BTU/hr 3,950,000 2,750,000 2,200,000 1,900,000 1,680,000 1,520,000 1,400,000 1,300,000 1,220,000 1,150,000 1,020,000 - - - - - - - - -
kW 615 428 346 290 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Maximum Capacity of Pipe in BTU/hr and kW for Gas Pressures of 14 in. W .C. (0.5 p si) or Less and a Pressure Drop of 0.5 in. W .C.
(based on 1.53 Specific Gravity Gas w/Heating V alue of 2,500 BTU’s/Ft
Length of Pipe in Feet (Metres)
Maximum Capacity of Pipe in BTU/hr and kW for Gas Pressures of 14 in. W .C. (0.5 p si) or Less and a Pressure Drop of 0.5 in. W .C.
(based on 0.60 Specific Gravity Gas w/Heating Value of 1,000 BTU’ s/Ft
Length of Pipe in Feet (Metres)
3
)
3
)
20
Page 21
GAS CONNECTIONS
WARNING
THIS BOILER IS NOT INTENDED TO OPERATE A T GAS SUPPLY
PRESSURE OTHER THAN SHOWN ON THE RATING PLATE.
EXPOSURE TO HIGHER GAS SUPPLY PRESSURE MA Y CAUSE
DAMAGE TO GAS VALVES WHICH CAN RESULT IN FIRE OR
EXPLOSION. IF OVERPRESSURE HAS OCCURRED SUCH AS
THROUGH IMPROPER TESTING OF GAS LINES OR EMERGENCY
MALFUNCTION OF THE SUPPL Y SYSTEM, THE GAS V ALVES MUST
BE CHECKED FOR SAFE OPERATION. MAKE SURE THAT THE
OUTSIDE VENTS ON THE SUPPLY REGULATORS AND THE
SAFETY VENT V AL VES ARE PROTECTED AGAINST BLOCKAGE.
THESE ARE PARTS OF THE GAS SUPPLY SYSTEM, NOT THE
BOILER. VENT BLOCKAGE MA Y OCCUR DURING ICE BUILD-UP
OR SNOW STORMS.
threads of pipe joints. Do not apply compound to the first two
threads. Use compounds resistant to the action of liquefied
petroleum gases.
THE BOILER MUST BE ISOLA TED FROM THE GAS SUPPLY PIPING
SYSTEM BY CLOSING ITS MAIN MANUAL GAS SHUT -OFF V AL VE
DURING ANY PRESSURE TESTING OF THE GAS SUPPL Y PIPING
SYSTEM AT TEST PRESSURES EQUAL TO OR MORE THAN 1/2
PSIG.
1. CORRECT GAS - Make sure gas on which the boiler will operate
is the same as that specified on the rating plate. Do not install
the boiler if equipped with a different type of gas. Consult your
gas supplier.
2A. SIZING GAS SUPPLY LINE (For single boiler installations).
See table 15.
WHEN LOCAL CODES REQUIRE A MAIN MANUAL SHUT-OFF
VAL VE OUTSIDE THE BOILER JACKET , A SUIT ABLE MAIN MANUAL
SHUT-OFF VALVE MUST BE INSTALLED IN A LOCATION
COMPL YING WITH THOSE CODES.
IT IS IMPORT ANT TO GUARD AGAINST GAS V ALVE FOULING FROM
CONT AMINANTS IN THE GAS WA YS. SUCH FOULING MA Y CAUSE
IMPROPER OPERATION, FIRE OR EXPLOSION. IF COPPER
SUPPL Y LINES ARE USED THEY MUST BE APPROVED FOR GAS
SERVICE.
BEFORE ATTACHING THE GAS LINE BE SURE THAT ALL GAS
PIPE IS CLEAN ON THE INSIDE.
TO TRAP ANY DIRT OR FOREIGN MA TERIAL IN THE GAS SUPPL Y
LINE, A DIRT LEG (SOMETIMES CALLED DRIP LEG) MUST BE
INCORPORATED IN THE PIPING. THE DIRT LEG MUST BE
READILY ACCESSIBLE AND NOT SUBJECT TO FREEZING
CONDITIONS. INSTALL IN ACCORDANCE WITH RECOMMENDATIONS OF SERVING GAS SUPPLIERS. REFER TO
NATIONAL FUEL GAS CODE, ANSI Z223.1 OR CAN/CSA -B149.1
AND .2 (AND LA TEST ADDENDA).
Gas Pipe sizing may be larger than heater connections on
installations where a significant run of piping is required. To prevent
damage, care must be taken not to apply too much torque when
attaching gas supply pipe to gas inlet.
Fittings and unions in the gas line must be metal to metal type.
Apply joint compounds (pipe dope) sparingly and only to the male
2B. SIZING GAS SUPPLY LINE (For multiple installations of
two or more boilers). See tables 13 (Natural Gas) and 14
(Propane Gas).
T ABLE 15. SINGLE UNIT INST ALLATION, SUGGESTED
PIPE SIZE
DIST ANCE FROM METER
BTU INPUT 0-50' 51-100' 101-200' 201-300' 301-500'
990,000 2" 2 " 2 1/2" 2 1/2" 2 1/2"
1,300,000 2" 2 1/2" 2 1/2" 3 " 3 "
1,500,000 2" 2 1/2" 3 " 3 " 3 1/2"
1,850,000 2 1/2" 2 1/2" 3 " 3" 3 1/2"
2,100,000 2 1/2" 3" 3 " 3 1/2" 4 "
2,500,000 2 1/2" 3" 4 " 4 " 4 1/2"
Use tables 13 or 14, which are taken from ANSI booklet Z223.1,
NATIONAL FUEL GAS CODE, or CAN/CSA-B149.1and .2 (and latest
addenda) to size iron pipe or equivalent gas supply line. Table 13
is based on a pressure drop of 0.5 inches of water and a specific
gravity of 0.60 approximately that of natural gas. (LP gas has an
S.G. of about 1.53). If the service pressure is five inches water
column or less, use one pipe size larger than specified in tables
13-15 in order to minimize pressure drop in the line.
No additional allowance is necessary for an ordinary number of
fittings. Where it is necessary to use more than the average number
of pipe fittings i.e. elbows, tees, and valves in gas supply line, use
a pipe larger than specified to compensate for increased pressure
drop.
T ABLE 16. Orifice Size for Natural and Propane (LP) Gases (U.S. and Canadian Installations)
[Drill size unless otherwise indicated.]
Rating Input Number of
Model BTUH Burners Natural (Holes) Propane (Holes)
GB/GW 1000 990,000 10 0.111" (4X) 0.071" (3X)
GB/GW 1300 1,300,000 13 0.111" (4X) 0.071" (3X)
GB/GW 1500 1,500,000 15 0.111" (4X) 0.071" (3X)
GB/GW 1850 1,850,000 19 0.111" (4X) 0.071" (3X)
GB/GW 2100 2,100,000 21 0.111" (4X) 0.071" (3X)
GB/GW 2500 2,490,000 25 0.111" (4X) 0.071" (3X)
21
Page 22
WIRING CONNECTIONS
OPERA TION
ALL ELECTRICAL WORK MUST BE INST ALLED IN ACCORDANCE
WITH THE MOST RECENT VERSION OF THE NATIONAL
ELECTRICAL CODE/CANADIAN ELECTRICAL CODE AND MUST
CONFORM TO LOCAL REGULA TIONS.
AN ELECTRICAL GROUND IS REQUIRED TO REDUCE RISK OF
ELECTRIC SHOCK OR POSSIBLE ELECTROCUTION.
ground connection to the wire provided in the electrical supply
junction box on the boiler.
Grounding and all wiring connected to this boiler must conform to
the local code authority having jurisdiction or, in the absence of
such requirements, with the
70 or CSA-C22.2 most recent edition.
The Central Control Board and Ignition Control Boards that make
up the control system are micro-processor based which make
them vulnerable to voltage and amperage fluctuations in the power
supply. It is imperative that they be protected by a suitable
commercial-grade surge protection device.
IF ANY OF THE ORIGINAL WIRE, AS SUPPLIED WITH THE
APPLIANCE, MUST BE REPLACED, IT MUST BE REPLACED WITH
TYPE 105°C WIRE OR ITS EQUIVALENT.
The Genesis Hot Water Supply Boiler must be connected to a single
phase line source that is:
120 volts, 60 Hertz, and 30 Amps.
National Electrical Code, ANSI/NFPA
Make the
IMPORTANT
Only qualified personnel shall perform the initial firing of the heater.
At this time the user should not hesitate to ask the start-up
technician any questions regarding the operation and maintenance
of the unit. If you still have questions, please contact the factory or
your local A.O. Smith representative.
Lighting and Operating instructions are included with this manual.
By using these instructions, the user may be able to make minor
operational adjustments and save unnecessary service calls.
However the user should not attempt repairs, but should contact a
service technician or gas supplier.
GENERAL
Never operate the boiler without first making sure the boiler and
system are filled with water, in addition:
For hot water supply installations:
• Make sure a temperature and pressure relief valve is installed at
the boiler and, if used, the storage tank. Also check for leaks.
For heating boiler installations:
• Make sure that the boiler and system have been purged of air
and checked for leaks.
Also be sure to check the gas piping for leaks before beginning the
initial firing of the boiler.
The system controller, other than the factory-supplied tank probe
(e. g. Honeywell Aquastat) must be wired on the low voltage side of
the 24VAC rear junction box.
Refer to the Schematic Diagram (Figure 19) and the Connection
Diagram (Figure 20) for wire connections.
Fuse Protection
The 24 VAC circuitry is protected with a 3 amp auto fuse on the
ignition control boards and a 5 amp fuse on the Central Control
Board. If the fuse opens, a red LED located near the fuse will light
(see figures 14 and 15). If the red LED is illuminated, replace the
fuse. Repeated failure of the fuse is an indication of possible
damage to the ignition control. The 120V circuits of each ignition
control module is protected with a 10 amp fuse located inside the
control box.
Note: Four extra 3 amp fuses and one 5 amp fuse are supplied
with the boiler.
Recommended Replacement fuses:
3 Amp: Littlefuse automotive fuse PN 257003
5 Amp: Bussman Automotive fuse PN A TC5
FILLING AND PURGING FOR HEA TING
BOILER INST ALLATION
1. Fast fill system through bypass until pressure approaches
desired system pressure. Close bypass valve and permit
pressure to be established by the pressure reducing valve.
2. Vent all high points in system to purge system of air.
Provisions should be made to permit manual venting of radiators
or convectors.
FILLING FOR HOT WA TER SUPPL Y BOILER INST ALLA TION
1. Close the systems drain valve by turning handle clockwise.
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 be filled.
4. Close the hot water faucet as water starts to flow.
5. The heater is ready to be operated.
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PURGING OF GAS LINE
Gas line purging is required with new piping or systems in which
air has entered.
2. CHECK THE INPUT. SEE SECTIONS "INLET GAS PRESSURE:"
AND SEE NA TIONAL FUEL GAS CODE, ANSI Z223.1 OR CAN/
CSA - B149.1 AND .2 (AND LATEST ADDENDA) FOR
PROCEDURES.
CAUTION
PURGING SHOULD BE PERFORMED BY PERSONS
EXPERIENCED IN THIS TYPE OF GAS SERVICE T O AVOID RISK
OF FIRE OR EXPLOSION. PURGE DISCHARGE MUST NOT
ENTER CONFINED AREAS OR SPACES WHERE IGNITION CAN
OCCUR. THE AREA MUST BE WELL VENTILATED AND ALL
SOURCES OF IGNITION MUST BE DEACTIV A TED OR REMOVED.
BEFORE PLACING THE BOILER IN OPERATION, CHECK FOR
GAS LEAKAGE. USE A SOAP AND WA TER SOLUTION OR OTHER
MATERIAL ACCEPT ABLE FOR THE PURPOSE OF LOCATING GAS
LEAKS. DO NOT USE MA TCHES, CANDLES, FLAME OR OTHER
SOURCES OF IGNITION FOR THIS PURPOSE.
WARNING
THE GAS VAL VE MUST HA VE BEEN IN THE OFF POSITION FOR A T
LEAST 5 MINUTES. This waiting period is an important safety
step. Its purpose is to permit gas that may have accumulated in
the combustion chamber to clear. IF YOU DETECT GAS ODOR AT
THE END OF THIS PERIOD DO NOT PROCEED WITH LIGHTING.
RECOGNIZE THA T GAS EVEN IF IT SEEMS WEAK, MA Y INDICA TE
PRESENCE OF ACCUMULA TED GAS SOMEPLACE IN THE AREA
WITH RISK OF FIRE OR EXPLOSION. SEE THE FRONT PAGE
FOR STEPS TO BE T AKEN.
INLET GAS PRESSURE
DANGER
HOT WATER TEMPERATURES REQUIRED FOR AUTOMATIC
DISHWASHER AND LAUNDRY USE CAN CAUSE SCALD
BURNS RESULTING IN SERIOUS PERSONAL INJURY AND/OR
DEA TH. THE TEMPERA TURE A T WHICH INJURY OCCURS V ARIES
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 BA TH WA TER. NEVER LEA VE A CHILD OR DISABLED
PERSON UNA TTENDED IN A BATHTUB OR SHOWER.
THE WA TER HEA TER SHOULD BE LOCA TED IN AN AREA WHERE
THE GENERAL PUBLIC DOES NOT HAVE ACCESS TO SET
TEMPERA TURES.
The inlet gas pressure is measured by removing the low gas
pressure switch located on the main gas manifold which is
upstream of the unit's combination gas valves. The maximum
value specified in the table must not be exceeded. The minimum
values shown in table 17 must be maintained under both load and
no load conditions (static and dynamic). The combination gas
valves supplied with the boiler are for low pressure service. If
upstream pressure exceeds 14.0" W.C., an intermediate gas
pressure regulator of the lockup type must be installed.
TABLE 17.
Inlet Gas Pressure Nat. Gas Prop. Gas
Max. Inlet Pressure (Inches W.C.) 14.0 14.0
Min. Inlet Pressure (Inches W.C.) 6. 0 11.0
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 A T THE BURNER MANIFOLD EXCEED THA T ST ATED
ON THE BOILER RA TING PLA TE. OVERFIRING WILL RESUL T 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.
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 WA TER HEATER TEMPERATURE A T 120°F (49°C)
WILL REDUCE THE RISK OF SCALDS. Some states require
settings at specific lower temperatures. Table 18 below shows the
approximate time-to-burn relationship for normal adult skin.
T ABLE 18. 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.
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Lighting Instructions for the G(B/W) 1000 through 2500 models
FOR YOUR SAFETY READ BEFORE OPERA TING
WARNING: IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY , A FIRE OR
EXPLOSION MA Y RESUL T CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR
LOSS OF LIFE.
A. THIS APPLIANCE DOES NOT HAVE A PILOT. IT IS
EQUIPPED WITH AN IGNITION DEVICE WHICH
AUTOMA TICALL Y LIGHTS THE BURNER. DO NOT TRY TO
LIGHT THE BURNER BY HAND.
B. BEFORE LIGHTING: SMELL ALL AROUND THE APPLIANCE
AREA FOR GAS. BE SURE TO SMELL NEXT TO THE FLOOR
BECAUSE SOME GAS IS HEAVIER THAN AIR AND WILL
SETTLE ON THE FLOOR.
WHAT T O DO IF YOU SMELL GAS
• DO NOT TRY TO LIGHT ANY APPLIANCE.
• DO NOT TOUCH ANY ELECTRIC 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 DEP ARTMENT.
C. USE ONL Y YOUR HAND TO PUSH IN OR TURN THE GAS
CONTROL KNOB. NEVER USE TOOLS. IF THE KNOB WILL
NOT PUSH IN OR TURN BY HAND, DON’T TRY TO REPAIR
IT . CALL A QUALIFIED SERVICE TECHNICIAN. FORCE OR
ATTEMPTED REPAIR MAY RESULT IN A FIRE OR
EXPLOSION.
D. DO NOT USE THIS APPLIANCE IF ANY P ART HAS BEEN
UNDER WATER. IMMEDIATELY CALL A QUALIFIED
SERVICE TECHNICIAN TO INSPECT THE APPLIANCE AND
TO REPLACE ANY PART OF THE CONTROL SYSTEM AND
ANY GAS CONTROL WHICH HAS BEEN UNDER WA TER.
E . DO NOT OPERA TE APPLIANCE UNLESS UNIT IS FILLED
WITH WA TER AND W ATER LINES ARE FULLY OPEN.
OPERA TING INSTRUCTIONS
1. STOP! READ THE SAFETY INFORMATION THE
NEXT STEP ABOVE ON THIS LABEL.
2. SET THE SYSTEM CONTROLLER TO THE LOWEST
SETTING.
3. TURN OFF ALL ELECTRIC POWER TO APPLIANCE.
4. THIS APPLIANCE IS EQUIPPED WITH AN IGNITION
DEVICE WHICH AUTOMA TICALL Y LIGHTS THE BURNER.
DO NOT TRY TO LIGHT THE BURNER BY HAND.
5. REMOVE CONTROL ACCESS P ANEL.
6. REFER TO DIAGRAMS ABOVE. TURN TOP KNOB OF GAS
CONTROL CLOCKWISE
7. WAIT FIVE (5) MINUTES TO CLEAR OUT ANY GAS. THEN
SMELL FOR GAS, INCLUDING NEAR THE FLOOR. IF YOU
SMELL GAS,
TO “OFF” POSITION, (FIG. A).
TO TURN OFF GAS TO APPLIANCE
1. SET THE SYSTEM CONTROLLER TO THE LOWEST
SETTING.
2. TURN POWER SWITCH ON APPLIANCE TO “OFF”
POSITION.
3. REMOVE ACCESS P ANEL TO EXPOSE GAS CONTROL.
STOP ! FOLLOW “B” IN THE SAFETY INFORMATION
ABOVE ON THIS LABEL.
IF YOU DON’T SMELL GAS, GO TO THE NEXT STEP .
8. TURN TOP KNOB OF GAS CONTROL COUNTERCLOCKWISE
9. REPLACE CONTROL ACCESS P ANEL.
10. TURN POWER SWITCH TO “ON” POSITION.
11. SET THE SYSTEM CONTROLLER T O DESIRED SETTING .
12. IF THE APPLIANCE WILL NOT OPERA TE, FOLLOW THE
INSTRUCTIONS “TO TURN OFF GAS TO THE APPLIANCE”
AND CALL YOUR SERVICE TECHNICIAN OR GAS
SUPPLIER.
4. REFER TO DIAGRAMS ABOVE. TURN TOP KNOB OF GAS
CONTROL CLOCKWISE (TO “OFF” POSITION, (FIG. A).
5. REPLACE CONTROL ACCESS P ANEL.
TO “ON” POSITION, (FIG. B).
24
Page 25
Lighting Instructions for the G(B/W) 1000 through 2500 models
FOR YOUR SAFETY READ BEFORE OPERATING
WARNING: IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY, A
FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE,
PERSONAL INJURY OR LOSS OF LIFE.
A. THIS APPLIANCE DOES NOT HA VE A PILOT . IT IS EQUIPPED
WITH AN IGNITION DEVICE WHICH AUTOMATICALLY
LIGHTS THE BURNER. DO NOT TRY TO LIGHT THE BURNER
BY HAND.
B. BEFORE LIGHTING: SMELL ALL AROUND THE APPLIANCE
AREA FOR GAS. BE SURE TO SMELL NEXT TO THE FLOOR
BECAUSE SOME GAS IS HEAVIER THAN AIR AND WILL
SETTLE ON THE FLOOR.
WHAT T O DO IF YOU SMELL GAS
• DO NOT TRY TO LIGHT ANY APPLIANCE.
• DO NOT TOUCH ANY ELECTRIC 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 DEP ARTMENT.
C. USE ONL Y YOUR HAND TO TURN THE MAIN MANUAL GAS
VA LVE HANDLE. NEVER USE TOOLS. IF THE HANDLE WILL
NOT TURN BY HAND, DON’T TRY T O REPAIR IT. CALL A
QUALIFIED SERVICE TECHNICIAN. FORCE OR A TTEMPTED
REPAIR MA Y RESULT IN A FIRE OR EXPLOSION.
D . DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN
UNDER WA TER. IMMEDIA TELY CALL A QUALIFIED SERVICE
TECHNICIAN TO INSPECT THE APPLIANCE AND TO
REPLACE ANY P ART OF THE CONTROL SYSTEM AND ANY
GAS CONTROL WHICH HAS BEEN UNDER WA TER.
E . DO NOT OPERA TE APPLIANCE UNLESS UNIT IS FILLED
WITH WA TER AND WA TER LINES ARE FULL Y OPEN.
OPERA TING INSTRUCTIONS
1. STOP! READ THE SAFETY INFORMA TION ABOVE ON
THIS LABEL.
2 SET THE SYSTEM CONTROLLER TO THE LOWEST
SETTING.
3. TURN POWER SWITCH ON APPLIANCE TO “OFF”
POSITION.
4. TURN MAIN MANUAL GAS V ALVE T O “OFF” POSITION,
(FIGURE “B”). THE VA LVE IS “OFF” WHEN THE HANDLE IS
PERPENDICULAR TO THE GAS FLOW DIRECTION.
5. THIS APPLIANCE IS EQUIPPED WITH AN IGNITION
DEVICE WHICH AUTOMA TICALL Y LIGHTS THE BURNER,
DO NOT TRY TO LIGHT THE BURNER BY HAND.
6. WAIT FIVE (5) MINUTES TO CLEAR OUT ANY GAS. THEN
SMELL FOR GAS, INCLUDING NEAR THE FLOOR. IF YOU
SMELL GAS,
STOP! FOLLOW “B” IN THE SAFETY INFORMATION
ABOVE ON THIS LABEL. IF YOU DON’T SMELL GAS, GO
TO THE NEXT STEP .
7. TURN MAIN MANUAL GAS VAL VE TO “ON” POSITION,
(FIGURE “A”), THE VAL VE IS “ON” WHEN THE HANDLE IS
P ARALLEL TO THE GAS FLOW DIRECTION.
8. TURN POWER SWITCH TO “ON” POSITION.
9. SET THE SYSTEM CONTROLLER TO DESIRED SETTING.
10. IF THE APPLIANCE WILL NOT OPERA TE, FOLLOW THE
INSTRUCTIONS “TO TURN OFF GAS TO THE APPLIANCE”
AND CALL YOUR SERVICE TECHNICIAN OR GAS
SUPPLIER.
TO TURN OFF GAS TO APPLIANCE
1. SET THE SYSTEM CONTROLLER TO THE LOWEST SETTING.
2. TURN POWER SWITCH ON APPLIANCE TO “OFF” POSITION.
3. TURN MAIN MANUAL GAS VAL VE TO “OFF” POSITION, (FIGURE “B”). THE V AL VE
IS “OFF” WHEN THE HANDLE IS PERPENDICULAR TO THE GAS FLOW DIRECTION.
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Page 26
CONTROL SYSTEM
These jumpers are pre-set at the factory and should only be
adjusted by a qualified service technician.
DESCRIPTION OF MUL TI-ST AGE FIRING SYSTEM
The Central Control Board (CCB) is responsible for staging the
Ignition Control Boards (ICB) and monitoring safety limit devices,
control of circulation pump, power vent, alarm output and IRI gas
valves (only on IRI models). The thermostat also resides on the
CCB with inputs available for inlet, outlet and tank temperature
probes as well as an input for a remote 24 VAC thermostat. The
CCB has a display interface which connects to the Display Board
to show system status and failures. The CCB also has a set of DIP
switches which allows the user to control several system
parameters. (See Figure 14.)
Each stage requires an Ignition Control Board (ICB) which is
responsible for controlling a combustion blower, hot surface igniter
and gas valve. Each ICB is capable of monitoring gas valve power,
gas valve relay, flame sense and igniter current. The ICB is
designed to communicate with the Central Control Board (CCB).
Each ICB consists of identical hardware and software. Each stage
ICB is made unique through the use of circuit board jumpers which
allow the user to control such variables as stage identification and
blower/igniter usage. (See Figure 15 for jumper configurations.)
The Display Board allows the end user to monitor water temperature,
set-points, differentials, options, fault indications and error codes.
Display Board pushbuttons labeled "ADJUST", "SELECT" AND
"ENTER/RESET" enable the user to adjust set-points, differentials,
post-circulate time, reset the cycle count and reset the control
system during lock-out. Changes made to programmable features
are stored in non-volatile memory.
DIA-SCAN II DISPLA Y BOARD OPERATING PROCEDURES
The Display Board provides a user-friendly interface to the Central
Control Board. With the Display Board, the user can control
appliance functions and view the overall operating status of the
appliance. If an error condition occurs, the Display Board will indicate
the nature of the fault by illuminating a red LED. The display will
further define the fault by illuminating a red LED corresponding to
the stage on which the fault has occurred. Red and green LEDs
are associated with each stage to indicate either a fault or normal
operation. If the fault continues until the unit "locks out", the display
will show a three digit code in addition to the red LEDs. (See Table
19 for error code chart.) Under normal operating conditions, the
four digit LED display on the Display Board will continuously illustrate
the water temperature sensed at the inlet temperature probe. If dip
SW 1 OFF ON SELECTION:
ON
SW1
1 2 3 4 5 6 7 8
AHFEDCBG
Figure 14. Central Control Board's Dip Switch Configuration and Options
A 3 STAGE 4 STAGE EITHER 3 OR 4 STAGE SYSTEM
B 3 TRIALS 1 TRIAL EITHER 3 OR 1
C NO I RI IR I WHETHER SYSTEM IS IRI OR
D INLET TANK INLET OR TANK AS
E NO EXTERNAL EXTERNAL WHETHER EXTERNAL
F OUTLET 210°F OUTLET 240°F OUTLET MAXIMUM TEMPERA TURE
G 190°F 220°F MAX. SET-POINT TEMPERA TURE
H DEGREES °F DEGREES °C EITHER °F OR °C FOR DISPLAYED
26
DIP SWITCH CONFIGURA TION T ABLE
GAS VALVE GAS VALVE STANDARD
CONTROLLING PROBE
THERMOST A T THERMOSTAT THERMOSTA T IS USED
TEMPERATURE
Page 27
Figure 15. Ignition Control Board Jumper Settings
switch "D" on the Central Control Board is placed in the "ON"
position, it will show the temperature at the tank probe. (See Figure
14.) The push buttons on the Display Board allow the user to
program and view several system parameters described in the
following text. The Display Board is connected to the Central Control
Board through a 6 conductor cable assembly with modular plug
terminations. In addition, an 8 conductor modular jack on the Display
Board allows for connecting a remote display board.
When power is applied to the Control System, the Display Board
will initially run through a self-diagnostic test, and then display the
inlet temperature. To display a specific setting or temperature,
press the SELECT push-button until the appropriate LED is
illuminated (see Figure 16). After 5 seconds, the Display Board
will automatically revert to displaying the Inlet temperature. Pressing the ENTER/RESET push-button will hold the display in the
indicated mode until the SELECT push-button is pressed.
With the display board, the user can make adjustments to many of
the appliance’s control features. This includes the following:
Options/Features Setting Procedures
• Set Appliance Stage Temperature Set-point Value
• Set Appliance Stage Switching Differential Value
• Select Appliance Post-Circulate Time
• Check Appliance Cycle Count
• View Last Error Encountered by Control
• Control the water temperature in a storage tank
Green Status Lights
Green LEDs indicate when a given stage has sensed flame and is
in the heating state. They also are used to indicate when the
Set-Point differential for a given stage is being viewed or adjusted.
(See Figure 16.)
STAGE 1: Stage One in Operation
STAGE 2: Stage Two in Operation
STAGE 3: Stage Three in Operation
STAGE 4: Stage Four in Operation
Red Fault Lights
The Red LEDs are illuminated to show faults and help in trouble
shooting. There are three faults (High Gas Fail, LWCO and Power
Vent Fail) listed as "Optional" which are only functional when the
particular "Optional" equipment is included with the boiler. The red
stage LEDs indicate on which stage a given fault has occurred.
(See Figure 16.)
Blocked Flue: Blockage in Flue
Probe Fail: One of the controlling Probes has failed
Insufficient Air: Not enough Air to Close Switch
Circulate Fail: Flow Switch Not Closed
Gas Valve Fail: Relay for Gas Valve in Incorrect State
High Limit: High Limit has been Exceeded
Flame Fail: No Flame Sensed upon Ignition
Igniter Fail: Igniter did not reach Minimum Amperage
Low Gas Fail: Gas Pressure too low to Close Switch
27
Page 28
Figure 16. Display Board
High Gas Fail: Gas Pressure at Manifold too High
LWCO: Low water Cutoff activated. Not enough water.
Power Vent Fail: Not Enough Air to Close Switch
Stage One: Failure on Stage One
Stage Two: Failure on Stage Two
Stage Three: Failure on Stage Three
Stage Four: Failure on Stage Four
Yellow Parameter Set Lights
The five yellow parameter set lights allow the user to view system
set points and options. In conjunction with the four green stage
LEDs, the user can monitor and change settings on the various
stages. (See Figure 16.)
Inlet*: Temperature shown is Inlet Water
Temperature.
Outlet: Temperature shown is Outlet Water
Temperature.
Set-Point**: Indicated probe set-point is being
displayed.
Set-Point Differential: Shows differentials of each stage.
Standby: Indicates Set-Point is Satisfied. Boiler
in Idle State.
*Defaults to tank probe temperature when Dip Switch "D" on
Central Control Board is Switched to the "ON" position.
(See Figure 14.)
**Shows set-point temperatures for Inlet/Tank or Outlet in
conjunction with yellow parameter lights. See temperature
probe section below.
TEMPERA TURE PROBES
All units come with two temperature probes connected to the Inlet/
Outlet header. Additionally , an optional tank probe (thermistor type)
or 24V thermostat/aquastat can be connected to the unit. The probes
can be categorized as two types: controlling probes and safety
limit probes. Controlling probes can control the staging of the
boiler. Safety limit probes are used as resettable high limit switches.
The two controlling probes are the inlet probe and the tank probe.
The function and setting of the probes is further described in the
following sections.
Outlet Probe
The Outlet Temperature/ECO probe is located on the left side of the
header and has two sets of wires embedded in it. The black wires
sense the temperature at the probe. Their output is shown on the
display screen when the "OUTLET" LED is illuminated. The red
wires control the ECO (Emergency Cutoff) which shuts down the
unit if the water temperature exceeds 250°F (121°C) and requires
a manual reset of the boiler. The outlet probe functions as a
automatically resettable high limit and is not considered a controlling
probe on the boiler, which means it cannot be set to control the
staging of the unit. Depending on the application of the boiler, the
probe is set to one of two settings. In GW applications, the maximum
Outlet Set Point is 210°F (99°C) and in GB applications it is 240°F
(115°C). The Outlet probe Set Point can be adjusted between
these two values using Dip Switch "F" on the Central Control Board
inside the control box. (See Figure 14.)
To view the current programmed temperature set-point for the Outlet Temperature probe:
1. Press the SELECT push-button on the display board until both
the Set-Pt LED and Outlet Water Temperature LED (see
Figure 16) are illuminated.
2. The LED display will show the current set-point temperature.
Note: Under no circumstances should the Outlet/ECO be set
to exceed 210°F (99°C) in applications where the boiler
is heating potable water. Failure to observe this will
void the warranty .
Inlet Probe
The Inlet probe is located on the right side of the Inlet/Outlet header.
It has one set of blue wires embedded in it which senses the
temperature at the probe. The Inlet Probe is considered a controlling
probe and can be used to control the staging of the unit. The inlet
probe set-point is fully adjustable between the factory set minimum
value of 80°F (25°C) and a user controlled maximum value which
will depend on unit's application. In GW applications, the maximum
Inlet Set-Point is 190°F (88°C) and in GB application it is 220°F
(104°C). The Inlet probe Set-Point can be adjusted between these
two maximum values using Dip Switch "G" on the Central Control
Board which is located inside the control box. (See Figure 14.)
To change or view the current programmed temperature set-point
for the Inlet Temperature probe value:
28
Page 29
1. Press the SELECT push-button on the display board until both
the Set-Pt LED and Inlet Water Temperature LED (see
Figure 16) are illuminated.
2. The LED display will show the current set-point temperature.
3. Press and hold the ADJUST push-button. The displayed
temperature will either increase or decrease. To alternate
between increasing or decreasing the temperature, release
then press and hold the ADJUST push-button.
4. When the desired set-point temperature is reached, release
the ADJUST push-button.
5. Press the ENTER/RESET push-button once, this enters the
selected set-point temperature into controller memory.
6. The appliance will now control the temperature to the desired
set-point value.
7. For setting the stage differentials, see the section labeled
Procedure for Setting Stage Differential.
NOTE: The boiler must complete a full cycle in order for the
new setting to take effect. If the unit is turned off prior
to a complete cycle the setting will be lost and the
previous setting will remain in effect.
24 VAC System Controller (Optional)
A 24 VAC thermostat/aquastat can be implemented as a system
controller on Genesis units. The connection for such devices is
located in the 24 VAC junction box at the rear of the unit. A 24 VAC
thermostat/aquastat can only be used as an "On/Off" switch for the
unit. The actual controlling of the staging will be through either the
inlet or tank probe. To use a 24 VAC system controller, dip switch "E"
on the CCB must be switched to the "on" position. See Figure 14.
Tank Probe (Optional)
In addition to the Inlet and Outlet/ECO Probes, units can be
optionally equipped with a tank Probe. The connection for the tank
probe is located in the 24 VAC junction box at the rear of the unit.
The tank Probe can be configured to control the staging of the unit.
See Tank Probe Installation section on page 17 for additional
information.
Procedure for Setting Tank Probe Temperature
If you have a GW hot water supply boiler, and have installed the t ank
probe, below are the instructions on how to adjust the water
temperature set-point.
1. Press the SELECT push-button on the display board until both
the Set-Pt LED and Inlet Water Temperature LED (see
Figure 16) are illuminated.
2. The LED display will show the current set-point temperature.
3. Press and hold the ADJUST push-button. The displayed
temperature will either increase or decrease. To alternate
between increasing or decreasing the temperature, release
then press and hold the ADJUST push-button.
4. When the desired set-point temperature is reached, release
the ADJUST push-button.
5. Press the ENTER/RESET push-button once, this enters the
selected set-point temperature into controller memory.
6. The appliance will now control the temperature to the desired
set-point value.
7. For setting the stage differentials, see the section labeled
Procedure for Setting Stage Differential.
Procedure for Setting Stage Differential
Once the system control and set-point temperature has been
entered, the switching differentials for the staging of the unit must
be established. To facilitate proper operation and maximize
appliance performance, each stage has a programmable
operating switching differential or “hysteresis” about the set point.
This means a call for heat for a particular stage will become active
when the water temperature measured at the controlling
temperature sensing probe drops to the set-point value minus the
switching differential value. It is necessary to set three set-point
differential values for three stage units and four for four stage. The
burner will remain on until the water temperature measured at
controlling probe reaches the stage set-point value. The switching
differential value is fully programmable from 0° F to 20°F (0°C to
11°C) using the push-button(s) located on the Display Board.
To change or view the current programmed switching differential:
1. Press the SELECT push-button on the display board until both
the Set-Pt Diff. and green Stage One LED (see Figure 16) are
illuminated.
2. The LED display will show the current differential for stage
one.
3. Press and hold the ADJUST push-button. The displayed value
will either increase or decrease. To alternate between
increasing or decreasing the differential, release then press
and hold the ADJUST push-button.
4. When the desired Set-Pt differential is reached, release the
ADJUST push-button.
5. Press the ENTER/RESET push-button once, this enters the
selected set-point deferential into controller memory. To view
the Set-Pt minus the Set-Pt differential, press and hold the
"ENTER" push-button. This will be the "turn-on" temperature
for Stage One and the "turn-off" temperature for Stage Two.
6. Repeat steps 2 through 5 for the rest of the stages.
7. The appliance will now control temperature utilizing the
desired differentials.
Example:
Application: Hydronic Heating
Desired System Temperature: 185°F (85°C)
Stage Differentials: 5°F (3°C) per Stage.
Note: The user must first choose which probe is to control the
staging of the unit. The controlling probe will be either the inlet or
tank probe. (If the tank probe is used to regulate loop temperature
in hydronic applications (GB Models), make sure it is located on
the return side of the closed loop.) Use Dip Switch "D" on the
Central Control Board to make this selection. See Figure 14.
Set the stage differentials using the procedure described in the
Procedure for Setting Stage Differential section of the document.
Setting the control as described in the above example (5°F
differentials for each stage) will give the following stage set-points.
Stage One
Off Temperature: 185°F (85°C)
On Temperature: 180°F (82°C)
Stage Two
Off Temperature: 180°F (82°C)
On Temperature: 175°F (79°C)
Stage Three
Off Temperature: 175°F (79°C)
On Temperature: 170°F (77°C)
Stage Four
Off Temperature: 170°F (77°C)
On Temperature: 165°F (74°C)
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Procedure for Setting Pump Delay
The Controller is factory set with a 45 second post circulate function.
With the Display Board, the user has the capability to choose
between a 45, 90, or 180 second post circulate time period, or turn
the pump on continuously. This provides flexibility in selecting the
post circulate time to meet specific installation requirements, and
improves the efficiency of the circulating pump operation.
To change or view the current programmed post-circulating time:
1. Press the SELECT push-button on the display board until the
LED display reads "OP" (Options). See Figure 16.
2. To enter into the options mode, press the ENTER/RESET
push-button.
3. The display will illustrate "Crcu". Enter this mode by
pressing the ENTER/RESET push-button.
4. The display will now illustrate the current post circulate time.
Press the ADJUST push-button to select the desired post
circulate time (45, 90, 180, "con").
5. When you have selected the desired post circulate time mode,
press the ENTER/RESET push-button once, this enters the
selected post circulate time into controller memory.
6. The display will automatically return to illustrating the
controlling probe temperature after five (5) seconds.
Last Error Mode
In this mode, the Display Board will illustrate the last error which
caused the unit to "lock-out". When this mode is entered the three
digit failure code that was in memory last will be displayed.
(See table 19 for error codes.) For example, if the appliance
"locked-out" due to insufficient air on stage one, the display will
show 041. To enter into this mode, perform the following steps:
1. Press the SELECT push-button on the display board until the
LED display reads "OP" (Options). See Figure 16.
2. To enter into the options mode, press the ENTER/RESET
push-button.
3. The display will illustrate "Crcu". Press the SELECT
push-button until the display illustrates "Ler". Enter this mode
by pressing the ENTER/RESET push-button.
4. The display will illustrate the last error detected by the control.
5. The display will automatically resort to illustrating the
controlling probe temperature after five (5) seconds.
Display Stage Cycle Count
The Central Control Board counts the number of cycles each stage
of the appliance has operated by counting how many times the gas
valve(s) are energized. To check the cycle count for each stage,
perform the following procedure:
1. Press the SELECT push-button on the display board until the
LED display reads "OP" (Options). See Figure 16.
2. To enter into the options mode, press the ENTER/RESET
push-button.
3. The display will illustrate "Crcu". Press the SELECT
push-button until the display illustrates "CC". Enter this mode
by pressing the ENTER/RESET push-button.
4. The display will now illustrate the current number of cycles
stage one has fired. Notice that the green Stage One LED is
illuminated. Pressing the ENTER/RESET button again will
cause the green Stage Two LED to illuminate and the cycle
count for stage two will be displayed on the screen. Cycle
counts for the other stages can be viewed in a similar fashion.
5. To reset the cycle count to zero, press the ADJUST pushbutton. Press the ENTER/RESET push-button to
successfully reset the cycle count. If the ENTER pushbutton is not pressed, the reset function will not be saved and
the original cycle count will continue to increment on
each gas valve operation.
6. The display will automatically return to illustrating the
controlling probe temperature after five (5) seconds.
Appliance Operating Sequence
1. When power is applied to the control system, the Display Board
will initially run through a self-diagnostic routine, and then go
into its operating mode, displaying the temperature sensed
at the Inlet probe.
2. If the Central Control Board determines the actual water
temperature at the controlling temperature probe is below the
programmed temperature set-point minus the switching
differential, and the thermostat circuit or tank probe circuit is
closed, a call for heat is activated.
3. The control then performs selected system diagnostic checks.
This includes confirming the proper state of the ECO/High
Limit device, flow switch*, and pressure switches.
*Note: Correct water flow is vital to the operation of the boiler .
See table 4 in the Installation manual for requirements on flow,
head loss and heat exchanger pressure drop.
4. If all checks are successfully passed, the circulating pump
circuit is energized. Once the flow switch has closed, all
combustion blowers will energize for a 30 second pre-purge
cycle.
5. When the pre-purge cycle is complete, all blowers except stage
1 will drop out. Power is applied to the stage 1 ignitor element
for the ignitor warm-up period.
6. The control will verify ignitor current. After the verification, the
gas valve will open, allowing gas to enter the burner.
7. After an additional 1 second, the control will monitor the flame
sense probe to confirm a flame is present. If a flame is not
verified within 4 seconds, the gas valve is immediately closed.
The control will initiate an 15 second inter-purge period and
return to step 2, unless dip switch "B" is in the "ON" position,
see fig. 14, in which case it will proceed to "lock-out".
8. If a flame is confirmed, stage two will be activated. The blower
associated with stage two will start. Once the blower has
been proven, igniter two will begin its warm-up period.
(This is true on all units except the 1000 which has only one
igniter.) After the igniter current has been proven, stage two
will begin a trial for ignition.
9. Stage three will activate after flame is proven on stage two. If
applicable, the blower associated with stage three will begin.
Once the blower has been proven, a trial for ignition will begin
on stage three. If flame is not proven, there will be a 15
second interpurge on stages with an associated blower. The
boiler will then begin additional trials for ignition. On stages
without an associated blower, a five second delay will occur
before the gas valves are opened for additional trials for
ignition.
Note: Stages on which no blower or igniter is present will
bypass the blower and igniter proving periods. The gas valves will
open five seconds after a call for heat is initiated on the stage.
10. All stages will remain running until the set point for a given
stage is satisfied. If all stages are initiated, stage four will
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drop out first followed by stages three, two and one. T o achieve
maximum efficiency, stages will reignite if the system water
temperature drops below the stage Set Point minus the Set
Point Differential.
NOTE: Cleaning of main burners.
Shut off all gas and electricity to unit.
1. Remove main burners from unit.
Note: Once a stage is satisfied, the blower associated with that
stage will allow a 25 second postpurge before it deactivates.
11. Once all of the stages have been satisfied, the pump will run
for the programmed post-circulate cycle (factory default 45
seconds). See Procedure for Setting Pump Delay on page 30
of the manual.
12. The control now enters the idle state. This is indicated on the
display by the "Standby" LED. The control will continue to
monitor temperature and the state of other system devices. If
the water temperature at the designated system controller
drops below the set-point value minus the switching
differential, and the thermostat circuit or tank probe circuit
closes, the control will return to step 2 and repeat the entire
operating cycle. During this idle state, if the control detects an
improper operating state for external devices such as the ECO
switch, air pressure switch, gas pressure switch, etc., the
appropriate LED(s) on the Display Board will illuminate
indicating the nature of the fault.
PREVENTATIVE MAINTENANCE
These boilers are designed to give many years of efficient and
satisfactory service when properly operated and maintained. To
assure continued good performance, the following
recommendations are made.
2. Check that burner venturi and ports are free of foreign matter.
3. Clean burners with bristle brush and/or vacuum cleaner.
DO NOT distort burner ports.
4. Reinstall burners in unit. Ensure that all the screws on the
burner flange are tightened securely so that the gasket will
provide a good seal. Also, ensure that each orifice is centered
with the venturi opening of every burner. The washer of the
orifice must be inserted a minimum of 1/4" into the burner
tube. This is critical for proper operation. See Figure 18.
5. Also check for good flow of combustion and ventilating air to
the unit.
This is a powered burner and the flame is not supposed to be on
the burner. The flame should be just above the burner deck
approximately 1/8” and blue in color (see Figure 17).
Visually check flame characteristics through the view port located
under the left-hand header on the boiler. Figure 17 shows the
normal flame condition. Also, refer to the flame label on the unit
(adjacent to the view port).
The area around the unit should be kept clean and free from lint
and debris. Sweeping the floor around the boiler should be done
carefully. This will reduce the dust and dirt which may enter the
burner and heat exchanger, causing improper combustion and
sooting.
MAIN BURNERS
Check main burners every three months for proper flame
characteristics.
The main burner should display the following characteristics:
• Provide complete combustion of gas.
• Cause rapid ignition and carry over of flame across entire burner.
• Give reasonably quiet operation during initial ignition, operation
and extinction.
• Cause no excessive lifting of flame from burner ports
(see Figure 17).
If the preceding burner characteristics are not evident, check for
accumulation of lint or other foreign material that restricts or blocks
the air openings to the burner or boiler.
Figure 18. Orifice Insertion
After placing the boiler in operation, check the ignition system safety
shut-off devices for proper operation. To accomplish this with the
main burners operating, close the valve on the manifold. Within
four seconds the main burners should extinguish. If this does not
occur immediately, discontinue gas supply by closing main manual
shut-off and call a qualified serviceman to correct the situation. If
the burners extinguish, then light boiler in accordance with lighting
and operating instructions.
For installations above 4,500 feet (1350 m), refer to HIGH AL TITUDE
INSTALLATIONS in the installation section.
Figure 17. Normal Flame Characteristics
THE FLOW OF COMBUSTION AIR TO THE BOILER MUST NOT BE
OBSTRUCTED.
THE BOILER AREA MUST BE KEPT CLEAR AND FREE FROM
COMBUSTIBLE MATERIALS, GASOLINE AND OTHER FLAMMABLE
V APORS AND LIQUIDS.
Any safety devices including low water cutoffs used in conjunction
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with this boiler 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. Periodic checks, at least
twice a year, should be made for water and/or gas leaks.
More frequent inspections may be necessary depending on water
conditions.
The boiler-mounted gas and electrical controls have been designed
to give both dependable service and long life. However, malfunction
can occur, as with any piece of equipment. It is therefore
recommended that all components be checked periodically by a
qualified serviceman for proper operation.
1. Turn off the electrical power, and manual gas shut-off.
• Allow boiler parts to cool before disassembly.
2. Remove the vent pipe.
• Check parts and chimney for obstructions and clean as
necessary.
3. Remove burners from boiler and other metal parts as required
to clean as necessary.
• Refer to parts list supplied with this manual for
disassembly aid.
4. Clean and reinstall the parts removed in steps 2 and 3.
• Be sure the vent pipe has a minimum upward pitch of 1/4"
per foot (2 cm/m) of length and is sealed as necessary.
5. Restore electrical power and gas supply to boiler.
• Check for gas leaks and proper boiler and vent operation.
RELIEF VAL VE
The safety relief valve should be opened at least twice a year to
check its working condition. This will aid in assuring proper
pressure relief protection. Lift the lever at the top of the valve several
times until the valve seats properly and operates freely.
DANGER
THE WA TER PASSING OUT OF THE VALVE DURING CHECKING
OPERATION MAY BE EXTREMELY HOT. BEFORE OPERATING
RELIEF V ALVE, MAKE SURE DRAIN LINE IS INST ALLED TO DIRECT
DISCHARGE TO A SAFE LOCATION SUCH AS AN OPEN DRAIN,
TO A VOID SCALDING OR W A TER DAMAGE.
WARNING
SHOULD OVERHEATING OCCUR OR THE GAS SUPPL Y F AIL TO
SHUT OFF, TURN OFF THE MANUAL GAS CONTROL VAL VE T O
THE APPLIANCE.
COMBUSTION AIR FILTER
If the combustion air supply to the boiler contains dust, dirt, drywall
dust etc. a filter must be installed. Air filter is not supplied with the
boiler as shipped from the factory. 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.
HEA T EXCHANGER PREVENTIVE MAINTENANCE
In most water supply systems some solids exist. As the water is
heated, these tend to drop out depositing as scale or lime. This
scale must be removed before the heat exchanger tubes become
blocked.
CAUTION
LIME ACCUMULATION CAN REDUCE THE LIFE OF THE
EQUIPMENT , REDUCE EFFICIENCY AND WASTE FUEL. BOILER
FAILURE DUE TO LIME OR SCALE BUILDUP VOIDS THE
WARRANTY.
DELIMING
The amount of calcium carbonate (lime) released from water is in
direct proportion to water temperature and usage. The higher the
water temperature or water usage, the more lime deposits are
dropped out of the water. This is the lime scale which forms in
pipes, boilers and on cooking utensils.
The usage of water softening equipment greatly reduces the
hardness of water. However, this equipment does not always
remove all of the hardness (lime). For this reason it is recommended
that a regular schedule for deliming be maintained.
BLOWER COMP ARTMENT
The blower compartment should be cleaned annually to remove
any dirt and lint that may have accumulated in the compartment or
on the blower and motor. Buildups of dirt and lint on the blower and
motor can create excessive loads on the motor resulting in higher
that normal operating temperatures and possible shortened service
life.
VENTING MAINTENANCE
It is recommended that the intake and exhaust piping of the
appliance be checked every 6 months for dust, condensate leakage,
deterioration and carbon deposits.
WARNING
DO NOT USE A NYLON BRUSH OR OTHER STATIC CREATING
MATERIAL TO CLEAN DUST AND CARBON DEPOSITS FROM
HEATING SURFACES AND VENT. SUCH DEPOSITS ARE
FLAMMABLE AND MA Y BE IGNITED BY STA TIC ELECTRICITY . USE
A MET AL BRUSH TO MINIMIZE THE DANGER OF EXPLOSION.
Qualified serviceman should follow this procedure when the boiler's
intake and exhaust piping need cleaning:
The time between cleaning will vary from two to six months
depending upon water conditions and usage. A change of
o
approximately 5
F (3°C) in the normal temperature rise through the
boiler is usually an indication that scale should be removed. For
long life, copper or brass is recommended for all valves, pipe and
fittings.
TUBE CLEANING PROCEDURE
MECHANICAL REMOV AL OF DEPOSITS
Establish a regular inspection schedule, the frequency depends
on the local water conditions and severity of service. Do not let the
tubes clog up solidly. Clean out deposits over 1/16" (1.6 mm)
thickness.
To service heat exchanger tubes remove return header casting,
side opposite the water connections. Use a U.S. standard 5/8"
deep socket ratchet to remove the nuts, exposing the tube ends.
Inspect to ensure tubes are free of scale and deposits. If scaled,
remove deposits with a stiff wire brush or mechanical tube cleaner
to bare metal. Reinstall return header casting. Flush system.
Note: Removal of the heat exchanger is not required.
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CAUTION
IF HEAT EXCHANGER MAINTENANCE REQUIRES TUBING
REPLACEMENT, SPECIAL PROVISIONS SHALL BE TAKEN TO
ENSURE THAT THE DAMAGED TUBES ARE CAREFULLY
REMOVED.
REPLACEMENT TUBES MUST BE PROPERLY INSTALLED AND
EXP ANDED INTO THE ROLLED TUBE TUB.
Display Board contains sixteen (16) red fault LED indicators to
help pinpoint the source of failures. In addition, the display will
inform the user on which stage the failure occurred by illuminating
a red Stage LED. In cases where the problem persists to lockout,
the appropriate red LEDs will remain illuminated and a three digit
error code will flash on the display screen. A summary of error
codes is given in table 19. The error codes are broken into two
categories: hard lockouts and soft lockout.
OVER-ROLLING, MISALIGNMENT OF TUBES OR IMPROPER
TIGHTENING OF THE ASSEMBLY MAY RESULT IN LEAKS OR
DAMAGE TO THE HEAT EXCHANGER. CONTACT YOUR
A. O. SMITH DEALER FOR DET AILED INSTRUCTIONS.
REPLACEMENT P ARTS
Replacement parts may be ordered through A. O. Smith dealers,
authorized servicers or distributors. Refer to the Yellow Pages for
where to call or contact (in United States) the A. O. Smith Water
Products Company, 5621 West 115th Street, Alsip, IL 60803,
1-800-433-2545 or (in Canada) A. O. Smith Enterprises Ltd., 768
Erie Street, Stratford, Ontario, Canada N5A 6T3, 519-271-5800.
When ordering parts be sure to state the quantity, part number and
description of the item including the complete model and serial
number as it appears on the product. Refer to the parts lists for
more information.
For Technical Assistance call A. O. Smith T echnical Information
Center at 1-800-527-1953.
TROUBLESHOOTING
Before any extensive troubleshooting, ensure that:
• Power (120 VAC) is supplied to the appliance.
• System control (tank probe, thermostat, etc.) is calling for
appliance operation (call for heat).
• Other contacts (switches) are closed (low water cutoff, flow
switch, limit controls, pressure switches, etc.)
• Gas supply pressure is within the maximum and minimum
operating ranges listed on the appliance rating plate/label.
• Appliance is wired according to wiring diagram.
NOTE: Shorting the thermostat wiring to ground in the 24 volt
circuit will blow the 3 amp fuse.
• All wire terminals/connectors are firmly attached to valves,
modules, switches, limit controls, etc.
• There has been no damage caused by freezing, inoperative
pumps, etc.
CAUTION
MAKE SURE POWER IS DISCONNECTED FROM MAIN BREAKER
BEFORE SERVICING.
CAUTION
LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN
SERVICING CONTROLS. WIRING ERRORS CAN CAUSE
IMPROPER FUNCTIONING OF UNIT RESUL TING IN PROPERTY
DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.
TROUBLESHOOTING IGNITION SYSTEM
The control system has several features to aid in troubleshooting
problems which may occur during operation. If a fault occurs, the
Hard Lockouts:
Hard lockouts require a manual reset accomplished by pressing
the Enter/Reset push-button on the Display Board. Cycling the
power "OFF" and "ON" will not reset the control.
Soft Lockouts:
Soft Lockouts also require a manual reset accomplished by
pressing the Enter/Reset push-button on the display board.
However, under a soft lockout condition, the control will re-initiate
an ignition process after one (1) hour provided the call-for-heat is
still present and will continue every hour until the unit is either reset
or ignites.
A description of the red fault LEDs and their corresponding
functions are as follows.
LED Controller Function
Blocked Flue Indicates a blockage or interference at the
appliance flue.
Temp. Probe Fail Indicates failure at one of the temperature
probes. Unit will "lock-out" only if controlling
probe fails.
Insufficient Air Indicates air pressure was too low to create
a sufficient differential to close the
differential pressure switch.
Circulate Fail Indicates water flow was too low to close
the flow switch.
Gas Valve Fail Monitors Gas Valve relay output. LED is ON
when the output relay supplying power to
the gas valve(s) is open.
High Limit Monitors ECO in the Outlet Temperature
probe. LED is ON when the ECO is open.
Flame Fail Monitors the Flame Sense Rod. LED is ON
when a signal from the flame rod is not
sufficient to indicate flame.
Igniter Fail Indicates igniter current was too low to meet
minimum value which allows trial for
ignition to continue.
Low Gas Fail Inlet gas pressure is not sufficient to close
gas pressure switch.
High Gas Fail* Manifold gas pressure is has exceeded
designed maximum value.
L WCO Fail* Indicates water level in system is too low for
safe operation.
Power Vent Fail* Air pressure at Power Vent Switch is not
sufficient for safe operation.
*Optional Equipment - LEDs will illuminate only if equipment is
connected to boiler.
Upon lockout, manually push the ENTER/RESET button on the
display panel to restart the boiler.
Verify proper operation af ter servicing.
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T able 19. Error Code Chart
FAUL T ERROR CODES LOCKOUT
COMMUNICA TIONS FAUL T (CCB TO ICB)
ST AGE 1: 001 HARD
ST AGE 2: 002 HARD
ST AGE 3: 003 HARD
ST AGE 4: 004 HARD
ECO/HIGH LIMIT : 01 0 HARD
NO GAS VA LVE POWER SENSED
ST AGE 1: 01 1 HARD
ST AGE 2: 012 HARD
ST AGE 3: 013 HARD
ST AGE 4: 014 HARD
LWCO 020 HARD
CIRCULA TE FAUL T (FLOW SWITCH) 03 0 SOFT
INSUFFICIENT AIR (AIR PRESSURE SWITCH)
ST AGE 1: 04 1 SOFT
ST AGE 2: 04 2 SOFT
ST AGE 3: 04 3 SOFT
ST AGE 4: 04 4 SOFT
BLOCKED FLUE 060 SOFT
POWER VENT 07 0 SOFT
GENESIS II CONTROL - F AUL T OPERA TION
IGNITER FAILURE
ST AGE 1: 081 HARD
ST AGE 2: 082 HARD
ST AGE 3: 083 HARD
ST AGE 4: 084 HARD
LOW GAS FAILURE 09 0 HARD
HIGH GAS FAILURE
ST AGE 1: 101 HARD
ST AGE 2: 102 HARD
ST AGE 3: 103 HARD
ST AGE 4: 104 HARD
GAS V ALVE RELA Y FAILURE
ST AGE 1: 1 1 1 HARD
ST AGE 2: 11 2 HARD
ST AGE 3: 11 3 HARD
ST AGE 4: 11 4 HARD
FLAME FAILURE
ST AGE 1: 121 HARD
ST AGE 2: 122 HARD
ST AGE 3: 123 HARD
ST AGE 4: 124 HARD
PROBE FAU LTS
OUTLET PROBE 131 HARD
INLET PROBE 132 HARD
REMOTE PROBE 133 HARD
IRI GAS VA LVE F AILURE 140 HARD
CPU FAUL T 210 HARD
For additional information please refer to the User’s Manual supplied with the boiler or contact:
A.O. Smith Technical Services 7 a.m. to 7 p.m. Central Time at:
1-800-527-1953
Our Internet Site is another source of information 24 hours a day .
http://www.hotwater.com
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NEW BOILER LIMITED W ARRANTY
A. O. Smith Corporation, the warrantor, extends the following LIMITED WARRANTY to the owner of this hydronic boiler:
1. If within TEN years after initial installation of the boiler, the heat exchanger shall prove upon examination by the warrantor to be defective in material
or workmanship, the warrantor, at his option, will exchange or repair such part or portion. This term is reduced to FIVE years if this boiler is used for
volume hot water supply purposes other than hydronic space heating.
a. This warranty is extended to the owner for all other parts or portion during the FIRST year following initial installation of this boiler.
b. The warranty on the repair or replacement of the part or portion will be limited to the unexpired term of the original warranty.
2. CONDITIONS AND EXCEPTIONS
This warranty shall apply only when the boiler is installed in accordance with local plumbing and building codes, ordinances and regulations, the
printed instructions provided with it and good industry practices. In addition, an appropriately sized safety relief valve certified to the ASME Boiler
and Pressure Vessel Code must have been installed and fresh water used for filling and makeup purposes;
a. This warranty shall apply only when the boiler is used:
(1 ) at temperatures not exceeding the maximum setting of its operative and/or high limit control;
(2 ) at water pressure not exceeding the working pressure shown on the boiler;
(3 ) when filled with boiler water, free to circulate at all times and with the heat exchanger free of damaging scale deposits;
(4 ) in a noncorrosive and non-contaminated atmosphere;
(5 ) in the United States, its territories or possessions, and Canada;
(6 ) at a water velocity flow rate, not exceeding or below the Boiler's designed flow rates;
b. Any accident to the boiler, any misuse, abuse (including freezing) or alteration of it, any operation of it in a modified form will void this warranty.
3. SERVICE AND REPAIR EXPENSE
Under this limited warranty the warrantor will provide only a replacement part. The owner is responsible for all other costs. Such costs may include
but are not limited to:
a. Labor charges for service removal, repair or reinstallation of the component part;
b. Shipping, delivery, handling, and administrative charges for forwarding the replacement part from the nearest distributor and returning the
claimed defective part to such distributor.
c. All cost necessary or incidental for any material and/or permits required for installation of the replacement.
4. LIMITATIONS ON IMPLIED W ARRANTIES
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 states or provinces do not allow limitations on how long an implied warranty lasts, so the above limitation may
not apply to you.
5. CLAIM PROCEDURE
Any claim under the warranty should be initiated with the dealer who sold the boiler, or with any other dealer handling the warrantor’s products.
If this is not practical, the owner should contact:
U.S. Customers Canadian Customers
A. O. Smith Water Products Company A. O. Smith Enterprises Ltd.
5621 West 115th Street P. O. Box, 310 - 768 Erie Street
Alsip, IL 60803 Stratford, Ontario N5A 6T3
Telephone: 800 323-2636 Telephone: (519) 271-5800
a. The warrantor will only honor replacement with identical or similar parts thereof which are manufactured or distributed by the warrantor.
b. Dealer replacements are made subject to in-warranty validation by warrantor.
6. DISCLAIMERS
NO OTHER EXPRESS WARRANTY HAS BEEN OR WILL BE MADE ON BEHALF OF THE WARRANTOR WITH RESPECT TO THE BOILER OR THE
INSTALLA TION, OPERA TION, REP AIR OR REPLACEMENT OF THE BOILER. THE W ARRANTOR SHALL NOT BE RESPONSIBLE FOR W A TER DAMAGE,
LOSS OF USE OF THE UNIT , INCONVENIENCE, LOSS OR DAMAGE TO PERSONAL PROPERTY OR OTHER CONSEQUENTIAL DAMAGE. THE W ARRANTOR
SHALL NOT BE LIABLE BY VIR TUE OF THIS WARRANTY OR OTHERWISE FOR DAMAGE TO ANY PERSONS OR PROPERTY , WHETHER DIRECT OR
INDIRECT , AND WHETHER ARISING IN CONTRACT OR TORT.
a. Some states or provinces do not allow the exclusion or limitation of the incidental or consequential damage, so the above limitations or exclusions
may not apply to you.
b. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state or province to province.
Fill in the following for your own reference. Keep it. Registration is not a condition of warranty. The model and serial number are found on the boiler’s
rating plate.
Owner_____________________________________________________________________________________________________________________
Installation Address___________________________________________________________________________________________________________
City and State or Province_____________________________________________________Postal/Zip Code____________________________________
Date Installed__________________________Model No.______________________________Serial No.________________________________________
Dealer’s Name_______________________________________________________________________________________________________________
Dealer’s Address________________________________________________________________Phone No. ____________________________________
FILL IN W ARRANTY AND KEEP FOR FUTURE REFERENCE
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REPLACEMENT PARTS
5621 W. 115TH STREET, ALSIP, IL 60803
Phone: 800-433-2545 Fax: 800-433-2515
www.hotwater.com E-Mail: parts@hotwater.com
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