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:
• 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.
SERIES 400, 401, 402, 403, 404, 405
2-STAGE UNITS
for buying this
Thank You
cost efficient, high recovery unit
from A. O. Smith Water Products Company
Please read through this informative manual and
pay special attention to the following:
ROUGH-IN DIMENSIONS/CAPACITIES PAGES 2 - 4
"FOREWORD" ON PAGE 5
"FEATURES" ON PAGES 6 - 7
"VENTING" ON PAGES 8 - 12
"GAS CONNECTIONS" 11 - 13
"INSTALLATION INSTRUCTIONS" ON PAGES 5 - 13
"WIRING DIAGRAM/SCHEMATIC" ON PAGES 14 - 15
"LIGHTING AND OPERATING" ON PAGES 19 - 20
"EMC5000 INSTRUCTIONS" ON PAGES 20 - 27
"SYSTEM EQUIPMENT INSTALLATION" PAGES 29 - 33
"TROUBLE SHOOTING" ON PAGES 27 - 28
"GENERAL MAINTENANCE" ON PAGES 34 - 35
"START-UP INSTRUCTIONS" ON PAGES 37 - 38
— Installation and service must be
"LIMITED WARRANTY" ON PAGE 39
performed by a qualified installer,
service agency or the gas supplier.
CAUTION
TEXT PRINTED OR OUTLINED IN RED CONTAINS
INFORMATION RELATIVE TO YOUR SAFETY. PLEASE
READ THOROUGHLY BEFORE INSTALLING AND USING
THIS APPLIANCE.
All Models - Maximum Supply Pressure: 14 In. W. C. (03.49 kPa)
Minimum Supply Pressure Natural Gas: 4.5 In.W. C. ( 01.22 kPa)
Minimum Supply Pressure Propane (LP) Gas: 11.0 In. W. C. ( 02.74 kPa)
FIGURE 4.
REAR
TABLE 1B. ROUGH-IN DIMENSIONS
ModelNatural Gas Natural GasGasGas(Inch)(Inch) Size (Inch) (Inch) (Inch) (mm)(inch)(mm) (Inch) (mm) (Inch) mm
TEXT PRINTED OR OUTLINED IN RED CONTAINS
INFORMATION RELATIVE TO YOUR SAFETY. PLEASE READ
COMPLETELY BEFORE USING APPLIANCE.
CAUTION
Label all wires prior to disconnection when servicing controls.
Wiring errors can cause improper and dangerous operation of
the boiler.
"Verify proper operation after servicing."
Detailed installation diagrams are in this manual. These
diagrams will provide the installer with a reference of materials
needed and a suggested method of piping. IT IS NECESSARY
THAT ALL WATER AND GAS PIPING, AND THE ELECTRICAL
WIRING BE INSTALLED AND CONNECTED AS SHOWN IN THE
DIAGRAMS.
CHECK THE DIAGRAMS THOROUGHLY BEFORE STARTING
INSTALLATION TO AVOID POSSIBLE ERRORS AND TO MINIMIZE
TIME AND MATERIALS COST. SEE FIGURES 1 THROUGH 4
AND TABLES 1A, 1B AND 1C.
This design complies with the current edition of ANSI Z21.13 CSA 4.9 for Gas-Fired Low-Pressure Steam and Hot Water
Boilers.
MAKE SURE THE GAS ON WHICH THE BOILER WILL OPERATE
IS THE SAME AS THAT SPECIFIED ON THE BOILER RATING
PLATE.
The boiler installation must conform to these instructions and
the requirements of the local authority having jurisdiction.
In the absence of local code requirements, the installation must
conform to the National Fuel Gas Code, ANSI Z223.1 or CAN/
CSA-B149.1-00 (current edition).
These manuals can be purchased from the Canadian
Standards Association, 8501 East Pleasant Valley Road,
Cleveland, OH 44131
.
REPLACEMENT PARTS
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, 500 Tennessee Waltz Parkway,
Ashland City, TN 37015, 1-800-433-2545 or (in Canada) A. O.
Smith Enterprises Ltd., 768 Erie Street, Stratford, Ontario, Canada
N5A 6T3, 800-265-8520. 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.
INSTALLATION CLEARANCES
Sufficient area should be provided at the front (2 feet minimum)
and at the water connection side (1 foot minimum) of the unit
for proper servicing. Sufficient clearance should be provided at
the return header side of the boiler to permit access to heat
exchanger tubes for cleaning. 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.
These boilers are approved for installation on noncombustible
flooring in an alcove with minimum clearance to combustibles of:
3 inches sides, and back; 3 inches top, front alcove, 6 inches
vent.
For installation on combustible flooring use the Combustible
Floor Kit. The combustible floor kit base adds 4" to the overall
height of the boiler, see Figure 9.
Two inch clearance is required from combustible construction to
hot water pipes.
LEVELLING
For Technical Assistance call A. O. Smith Technical Information
Center at 1-800-527-1953.
WARNING
THE WATER MANIFOLD IS NOT DESIGNED TO SUPPORT THE
WEIGHT OF THE WATER PIPING SYSTEM. AS ON ALL BOILER
INSTALLATIONS, SPECIAL CARE MUST BE TAKEN TO ENSURE
PROPER SUPPORT.
WARNING
UNDER NO CIRCUMSTANCES SHOULD THE EQUIPMENT
ROOM WHERE THE BOILER IS INSTALLED EVER BE UNDER
NEGATIVE PRESSURE. PARTICULAR CARE MUST BE TAKEN
WHEN EXHAUST FANS, COMPRESSORS, AIR HANDLING
EQUIPMENT, ETC., MAY INTERFERE WITH THE COMBUSTION
AND VENTILATION AIR SUPPLIES OF THIS BOILER.
Each unit must be checked after installation to be certain that it
is level.
CONDENSATION WARNING
Your boiler is not designed to operate with a boiler inlet water
temperature of less than 120°F (38°C). Colder inlet water
temperatures will result in significant condensation developing
on the heat exchanger. This situation can cause a corrosive
environment for the heat exchanger, burners and venting resulting
in premature damage, which could result in serious personal
injury or death. Damage caused by excessive condensation will
not be covered under the limited warranty.
For systems that use large volumes of cold water or systems
utilizing heavy water draws, condensation can be prevented by
using a bypass loop.
5
FEATURES
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.
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.
The T & P relief valve should have a temperature rating of 210°F,
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 of
the top of the tank, see Figure 20 and 22. 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.
SAFETY RELIEF VALVES
Your local code authority may have other specific relief valve
requirements not covered below.
WARNING
THE PURPOSE OF A SAFETY RELIEF VALVE IS TO AVOID
EXCESSIVE PRESSURE WHICH MAY CAUSE TANK EXPLOSION,
SYSTEM OR BOILER DAMAGE.
TO AVOID WATER DAMAGE A DRAIN LINE MUST BE
CONNECTED TO A SAFETY RELIEF VALVE TO DIRECT
DISCHARGE TO A SAFE LOCATION. A DRAIN LINE MUST NOT
BE REDUCED FROM THE SIZE OF THE VALVE OUTLET AND IT
MUST NOT CONTAIN ANY VALVES BETWEEN THE BOILER AND
THE RELIEF VALVE OR THE RELIEF VALVE AND THE DRAIN
EXIT. IN ADDITION, THERE SHOULD NOT BE ANY
RESTRICTIONS IN A DRAIN LINE NOR SHOULD IT BE ROUTED
THROUGH AREAS WHERE FREEZING CONDITIONS MIGHT
OCCUR. DO NOT THREAD OR CAP THE DRAIN LINE EXIT.
RESTRICTING OR BLOCKING A DRAIN LINE WILL DEFEAT THE
PURPOSE OF THE RELIEF VALVE AND MAY CREATE AN UNSAFE
CONDITION. INSTALL A DRAIN LINE WITH A DOWNWARD
SLOPE SUCH THAT IT NATURALLY DRAINS ITSELF.
If any safety relief valve is replaced, the replacement valve must
comply with the latest version of the ASME Boiler and Pressure
Vessel Code, Section IV (HEATING BOILERS). Select a relief
valve with a discharge rating NOT less than the boiler input, and
a set pressure NOT exceeding the working pressure of any
component in the system.
The storage tank temperature and pressure relief valve must
comply with the applicable construction provisions of the Standard
for Relief Valves for Hot Water Supply Systems, ANSI Z21.22 CSA 4.4 (current edition). The valve must be of the automatic
reset type and not embody a single-use type fusible plug, cartridge
or linkage.
FOR HOT WATER HEATING SYSTEMS, the boilers are shipped
with a 50 psi pressure relief valve. This relief valve is factory
installed in the water outlet header of the boiler, see Figure 1.
FOR HOT WATER SUPPLY SYSTEMS, the boilers are shipped
with a 125 psi pressure relief valve. This relief valve is factory
installed in the water outlet header of the boiler, see Figure 1.
This ASME-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, a CSA 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.
INSTALLATION INSTRUCTIONS
REQUIRED ABILITY
INSTALLATION OR SERVICE OF THIS BOILER REQUIRES
ABILITY EQUIVALENT TO THAT OF A LICENSED TRADESMAN
IN THE FIELD INVOLVED. PLUMBING, AIR SUPPLY, VENTING,
GAS SUPPLY AND ELECTRICAL WORK ARE REQUIRED.
LOCATION
When installing the boiler, consideration must be given to proper
location. Location selected should be as close to the stack or
chimney as practical with adequate air supply and as centralized
with the piping system as possible. This location should also
be such that the gas ignition system components are protected
from water (dripping, spraying, etc.) during appliance operation
and service [circulator replacement, control replacement, etc.].
• THE BOILER MUST NOT BE INSTALLED ON CARPETING.
• THE BOILER SHOULD NOT BE LOCATED IN AN AREA WHERE
IT WILL BE SUBJECT TO FREEZING.
• THE BOILER SHOULD BE LOCATED NEAR A FLOOR DRAIN.
• THE BOILER SHOULD BE LOCATED IN AN AREA WHERE
LEAKAGE FROM THE BOILER OR CONNECTIONS WILL NOT
RESULT IN DAMAGE TO THE ADJACENT AREA OR TO
LOWER FLOORS OF THE STRUCTURE.
WHEN SUCH LOCATIONS CANNOT BE AVOIDED, A SUITABLE
DRAIN PAN SHOULD BE INSTALLED UNDER THE BOILER.
Such pans should be fabricated with sides at least 2-1/2" deep,
with length and width at least 2" greater than the dimensions of
the boiler plus piping connections and must be piped to an
adequate drain. The pan must not restrict combustion air flow.
WARNING
THERE IS A RISK IN USING FUEL BURNING APPLIANCES IN
ROOMS OR AREAS WHERE GASOLINE, OTHER FLAMMABLE
LIQUIDS OR ENGINE DRIVEN EQUIPMENT OR VEHICLES ARE
STORED, OPERATED OR REPAIRED. FLAMMABLE VAPORS
ARE HEAVY AND TRAVEL ALONG THE FLOOR AND MAY BE
IGNITED BY THE IGNITER OR MAIN BURNER FLAMES CAUSING
FIRE OR EXPLOSION. SOME LOCAL CODES PERMIT
OPERATION OF GAS APPLIANCES IF INSTALLED 18 INCHES
OR MORE ABOVE THE FLOOR. THIS MAY REDUCE THE RISK
IF LOCATION IN SUCH AN AREA CANNOT BE AVOIDED.
FLAMMABLE ITEMS, PRESSURIZED CONTAINERS OR ANY
OTHER POTENTIAL FIRE HAZARDOUS ARTICLES MUST NEVER
BE PLACED ON OR ADJACENT TO THE BOILER.
OPEN CONTAINERS OF FLAMMABLE MATERIAL SHOULD NOT
BE STORED OR USED IN THE SAME ROOM WITH THE BOILER.
6
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.
CHEMICAL VAPOR CORROSION
Heat exchanger corrosion and component failure can be caused
by the heating and breakdown of airborne chemical vapors. Spray
can propellants, cleaning solvents, refrigerator and air
conditioning refrigerants, swimming pool chemicals, calcium
and sodium chloride, waxes, and process chemicals are typical
compounds which are corrosive. These materials are corrosive
at very low concentration levels with little or no odor to reveal their
presence.
Products of this sort should not be stored near the boiler. Also,
air which is brought in contact with the water boiler should not
contain any of these chemicals. If necessary, uncontaminated
air should be obtained from remote or outside sources.
MANUAL RESET HIGH TEMPERATURE LIMIT CONTROL
This device prevents the water temperature from reaching 250°F.
This device is located in the outlet temperature probe.
AUTOMATIC RESET
HIGH TEMPERATURE LIMIT CONTROL
CAUTION
LIMIT CONTROLS ARE NOT TO BE USED AS A THERMOSTAT.
This device prevents the outlet water temperature from reaching
the setpoint. Its operation is based on the feedback from the
outlet temperature probe. If the temperature exceeds the setpoint,
a fault is declared and the gas is shut off. The fault condition is
automatically cleared when the temperature drops below the
high limit setpoint minus the high limit differential. The factory
preset values (and the default high limit values) are 210°F for
GW models and 230°F for GB models. The user can adjust
these values between 90°F and 210°F for the GW models and
90°F and 235°F for the GB models. The factory preset value (and
the default high limit differential value) for both models is 20°F.
The user adjustable range is 1°F to 50°F.
TANK PROBE/INLET PROBE
FOR HOT WATER SUPPLY SYSTEMS (GW models), A tank probe
is supplied with each hot water supply boiler. When a tank probe
is connected to the system, the tank section on the UIM
temperature screen will display a temperature instead of dashes.
continuous operation). GB models require a field supplied
operating control be installed in the system. Such as: loop stat,
indoor/outdoor reset control, sequencing panel, or energy
management system. These types of controls connect to the
thermostat wires in the junction box on the boiler. Do not operate
this boiler using the internal high limits only, you must use an
operating stat as mentioned above.
CIRCULATING PUMP
The pump flow rate should not exceed the maximum
recommended flow rate, see Table 2.
FOR HOT WATER SUPPLY SYSTEMS (GW models), the circulating
pump is an integral part of the Boiler, see Figure 3. This pump
has been lubricated at the factory, and future lubrication should
be in accordance with the motor manufacturer's instructions
provided as supplement to this manual.
FOR HOT WATER HEATING SYSTEMS (GB models), the circulating
pump is NOT provided and must be field-installed.
SAFETY FLOW SWITCH (Supplied)
The safety flow switch is a safety device which is installed at the
water outlet of the unit to prevent main burner operation in the
event of inadequate water flow through the boiler.
This switch is connected to the CCB, and its status is displayed
on the "System Status" screen. An asterisk indicates switch
closure (water flowing).
LOW WATER CUTOFF (OPTIONAL)
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 Figure 23. To meet
code requirements the power connections for this switch can be
connected to the LWCO connections on the CCB, but the
independent contacts for feedback should not be. They should
be connected in series with the ECO. When connected in this
manner, the LWCO dipswitch on the CCB should be off. The
system will not recognize a low water fault condition as a LWCO
fault. It will respond with an ECO fault. 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. If a LWCO is desired, but not required by code, it can
be connected to the LWCO connections on the CCB and the
dipswitch should be turned to on. The system will then recognize
a low water fault condition as LWCO fault.
DRAIN VALVE (Not Supplied)
"Pigtails" of field-supplied wires should be spliced to "pigtails" of
tank probe and to "pigtails" at the junction box. See Figure 21 for
the tank probe installation. Operating control of the system will
be transferred to the tank probe when "Tank Cont" is selected on
dip switch #3 off "SW1" on the CCB.
In the absence of tank probe, the inlet probe can be used for
boiler stage control. Staging control will be transferred to inlet
probe when "Inlet" is selected on dip switch #3 on CCB. Make
sure to set the boiler pump for continuous operation.
FOR HOT WATER HEATING SYSTEMS (GB models) Due to the
various types of systems and operating conditions, no factory
operating control is supplied with the GB models. If no probe is
attached to the system, then the dip switch on the CCB should
be set to inlet control (and make sure that boiler pump is set for
Drain valves must be obtained and installed on each boiler and
tank for draining purposes.
AIR REQUIREMENTS
WARNING
FOR SAFE OPERATION, AN AMPLE SUPPLY OF AIR MUST BE
PROVIDED FOR PROPER COMBUSTION AND VENTILATION IN
ACCORDANCE WITH THE NATIONAL FUEL GAS CODE, ANSI
Z223.1 OR CAN/CSA-B149.1 (CURRENT EDITIONS) OR
APPLICABLE PROVISIONS OF THE LOCAL BUILDING CODES.
AN INSUFFICIENT SUPPLY OF AIR MAY RESULT IN A YELLOW,
LUMINOUS BURNER FLAME, CARBONING OR SOOTING OF
THE FINNED HEAT EXCHANGER, OR CREATE A RISK OF
ASPHYXIATION. DO NOT OBSTRUCT THE FLOW OF
COMBUSTION AND VENTILATION AIR.
7
UNCONFINED SPACE
In buildings of conventional frame, brick or stone construction,
unconfined spaces may provide adequate air for combustion.
If the unconfined space is within a building of tight construction
(buildings using the following construction: weather stripping,
heavy insulation, caulking, vapor barrier, etc.), air for combustion,
ventilation, must be obtained from outdoors or spaces freely
communicating with the outdoors. The installation instructions
for confined spaces in tightly constructed buildings must be
followed to ensure adequate air supply.
CONFINED SPACE
(a) U. S. INSTALLATIONS
When drawing combustion and dilution air from inside a
conventionally constructed building to a confined space, such a
space shall be provided with two permanent openings, ONE
WITHIN 12 INCHES OF THE ENCLOSURE TOP AND ONE
WITHIN 12 INCHES OF THE ENCLOSURE BOTTOM. Each
opening shall have a free area of at least one square inch per
1000 Btuh of the total input of all appliances in the enclosure, but
not less than 100 square inches.
If the confined space is within a building of tight construction, air
for combustion, ventilation, and draft hood dilution must be
obtained from outdoors. When directly communicating with the
outdoors or communicating with the outdoors through vertical
ducts, two permanent openings, located in the above manner,
shall be provided. Each opening shall have a free area of not
less than one square inch per 4000 Btuh of the total input of all
appliances in the enclosure. If horizontal ducts are used, each
opening shall have a free area of not less than one square inch
per 2000 Btuh of the total input of all appliances in the enclosure.
(b) CANADIAN INSTALLATIONS
Ventilation of the space occupied by the boiler(s) shall be provided
by an opening for ventilation air at the highest practical point
communicating with outdoors. The total 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
plus 1 square inch per 14,000 BTU in excess of 1,000,000
BTUH
BTUH. This opening(s) shall be located at, or ducted to, a point
neither more than 18" (450 mm) nor less than 6 inches (150
mm) above the floor level.
Where power vented equipment is used in the same room as
the boiler, sufficient air openings must be supplied.
UNDERSIZED OPENINGS MAY RESULT IN INSUFFICIENT AIR
FOR COMBUSTION.
Where an exhaust fan is installed in the same room with a boiler,
sufficient openings for air must be provided in the walls.
UNDERSIZED OPENINGS WILL CAUSE AIR TO BE DRAWN INTO
THE ROOM THROUGH THE CHIMNEY, CAUSING POOR
COMBUSTION. SOOTING MAY RESULT WITH AN INCREASED
RISK OF ASPHYXIATION.
2
).
2
/KW) up to and including 1,000,000
!
This boiler is approved to be vented as a Category I, Category III
(horizontal venting), or a Direct Vent appliance. The Horizontal
and Direct Venting options require a special vent kit.
When venting the Genesis Boiler through oversize chimney
(including masonry chimneys), additional care must be
exercised to assure proper draft. For proper operation, a
minimum draft of -0.02" w.c. and a maximum draft of -0.04" w.c.
must be maintained. In instances of excessive draft, a barometric
damper may be required to assist in maintaining the proper
draft. Draft should be measured 2 feet above the boiler vent
collar. The vent system must not have external runs greater
than that allowed by local codes or the National Fuel Gas Code.
WARNING
THE INSTRUCTIONS IN THIS SECTION ON VENTING THE
BOILER MUST BE FOLLOWED TO AVOID CHOKED COMBUSTION
OR RECIRCULATION OF FLUE GASES. SUCH CONDITIONS
CAUSE SOOTING OR RISKS OF FIRE AND ASPHYXIATION.
STANDARD (VERTICAL) VENTING, CATEGORY I
THIS BOILER MAY BE VENTED ACCORDING TO TABLE 5A AND 5C
(ALSO SEE FIGURE 6). AT LEAST TYPE B VENTING MUST BE USED
WITH THE STANDARD VENTING OPTION (thru-the-roof) USING THE
NATIONAL FUEL GAS CODE VENT TABLES.* TYPE B VENT PIPE
CANNOT BE USED IF THE BOILER IS VENTED HORIZONTALLY
(SEE PAGES 10 AND 11). ALL LOCAL UTILITY, STATE/PROVINCIAL,
REGULATIONS ON VENTING MUST BE FOLLOWED.
VENT SIZING, INSTALLATION AND TERMINATION SHALL BE IN
ACCORDANCE WITH THE NATIONAL FUEL GAS CODE, ANSI
Z223.1 OR CAN/CSA-B149.1 (CURRENT EDITIONS).
VENT CONNECTION
Model NumberVent Connector
G(W,B) 3005"
G(W,B) 4006"
G(W,B) 5006"
G(W,B) 6508"
G(W,B) 7508"
* For vent arrangements other than Table 5A 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 above the boiler vent collar.
8
VENTING THE BOILER
All boiler venting systems shall be installed in accordance with the
National Fuel Gas Code, ANSI Z223.1 or CAN/CSA-B149.1 (current
edition), or applicable provisions of the local building codes.
FIGURE 10. SINGLE PIPE VERTICAL TERMINATION
Vent connections must be made to an adequate stack or chimney
and shall be in accordance with the
National Fuel Gas Code,
ANSI Z223.1 or CAN/CSA-B149.1 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), 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 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.
CONNECTING BOILER TO A COMMON VENT
CAUTION
When the GENESIS boilers are commonly vented, additional
care must be exercised to assure proper draft. For proper
operation, a minimum draft of -0.02" w
-0.04" w.c. must be maintained AT EACH INDIVIDUAL BOILER.
In instances of excessive draft, a barometric damper may be
required to assist in maintaining the proper draft. Draft should
be measured 2 feet above EACH boiler vent collar.
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 8" diameter,
can be installed in heated and unheated areas and can pass
through floors, ceilings, partitions, walls and roofs, provided the
required clearance is observed.
At the time of removal of an existing boiler, the following steps
shall be followed with each appliance remaining connected to
the common venting system. Perform these steps while the
other appliances remaining connected to the common venting
system are not in operation.
Seal any unused openings in the common venting system.
Visually inspect the venting system for proper size and horizontal
pitch and determine there is not blockage or restriction, leakage,
corrosion and other deficiencies which could cause an unsafe
condition.
.c. and a maximum draft of
SINGLE PIPE HORIZONT
AL VENTING
Vent sizing, installation and termination shall be in accordance
with the NATIONAL FUEL GAS CODE, ANSI Z223.1 OR CAN/CSAB149.1. If applicable, all local, utility
, state/provincial regulations
on venting must be followed. This boiler may be vented according
to Table 5A and 5C. The exhaust vent pipe must be "Saf-T-Vent"
manufactured by Heat-Fab Inc. The exhaust vent material type is
AL 29-4C. This vent system must be 100% sealed with a
condensate trap located as close to the boiler as possible.
FIGURE 11. SINGLE PIPE HORIZONTAL TERMINATION
TABLE 5A. SINGLE PIPE HORIZONTAL AND VERTICAL VENTING
* When sizing exhaust piping and intake air piping, 90-degree elbows
are equivalent to 5 feet of straight pipe and 45-degree elbows are
equal to 3 feet of straight pipe.
Intake/Exhaust Installation Requirements:
1. The termination must be a minimum of 12 inches above
anticipated 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, (e.g., 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 from the exhaust terminal to any
window, gravity air inlet to a building, or from gas or electric
meter(s) is 6 feet horizontally, 4 feet below and 2 feet above.
4. The minimum distance from the exhaust terminal to an
inside corner formed by two exterior walls is 6 feet but 10
feet is recommended where possible.
5. Maintain a minimum distance of 4 feet from any soffit or
eave vent to the exhaust terminal.
6. Maintain a minimum distance of 10 feet 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.
9
8. Select the point of wall penetration where the minimum 1/4"
per foot 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 exhaust and intake air termination elbows
must be a minimum of 12 inches from the exterior wall.
DIRECT VENT HORIZONTAL AND VERTICAL VENTING
Vent sizing, installation and termination shall be in accordance
with the
CSA-B149.1 (CURRENT EDITIONS). If applicable, all local, utility,
state/provincial regulations on venting must be followed. This
boiler may be vented according to Table 5B and 5C. The exhaust
vent pipe must be "Saf-T-Vent" manufactured by Heat-Fab Inc.
The exhaust vent material type is AL 29-4C. This vent system
must be 100% sealed with a condensate trap located as close
to the boiler as possible.
The intake air piping can be PVC, CPVC, ABS or any suitable
intake air piping that can be sealed.
TABLE 5B. DIRECT VENT HORIZONTAL AND VERTICAL VENTING
* When sizing exhaust piping and intake air piping, 90-degree elbows
Intake/Exhaust Installation Requirements:
1. The exhaust and intake air termination must be a minimum
2. Due to normal formation of water vapor in the combustion
3. The minimum distance from the exhaust terminal to any
4. The minimum distance from the exhaust terminal to an inside
5. Maintain a minimum distance of 4 feet from any soffit or eave
6. Maintain a minimum distance of 10 feet from any forced air
7. Avoid areas where condensate drainage may cause problems
8. Select the point of wall penetration where the minimum 1/4"
9. The through the wall termination kit is suitable for zero
10.The mid point of the exhaust and intake air termination elbows
are equivalent to 5 feet of straight pipe and 45-degree elbows are
equal to 3 feet of straight pipe.
of 12 inches above anticipated snow or grade level which
ever is higher, see Figure 14.
process, horizontal terminations must not be located over
areas of pedestrian or vehicular traffic, (e.g. 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.
window, gravity air inlet to a building, or from gas or electric
meter(s) is 6 feet horizontally, 4 feet below and 2 feet
above.
corner formed by two exterior walls is 6 feet but 10 feet is
recommended where possible.
vent to the exhaust terminal.
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.
such as above planters, patios, or adjacent to windows where
the steam from the flue gases may cause fogging.
per foot of slope up can be maintained.
clearance to combustible materials.
must be a minimum of 12 inches from the exterior wall.
Direct venting into dead air
CAUTION
spaces such as alleys,
atriums and inside corners
can cause recirculation of flue
gases. Recirculation of flue
gases will cause sooting,
premature failure of the heat
exchanger and icing of the
combustion air intake during
severe cold weather. To
prevent the recirculation of
flue gases, maintain as much
distance as possible between
the combustion air intake and
the exhaust vent terminal.
FIGURE 12. DIRECT VENT HORIZONTAL TERMINATION AND
MINIMUM CLEARANCES
FIGURE 13. DIRECT VENT HORIZONTAL/VERTICAL TERMINATION
FIGURE 14. DIRECT VENT VERTICAL/HORIZONTAL TERMINATION
FIGURE 15. DIRECT VENT VERTICAL TERMINATION AND
MINIMUM CLEARANCES
10
TABLE 5C. INTAKE/VENTING CONFIGURATIONS, CATEGORIES AND MATERIALS
Source for CombustionExhaust VentingVenting CategoryApproved VentingCombustion Air
Air SupplyConfigurationMaterial RequiredIntake Material
Boiler Room Air (UsingVertical Natural DraftCategory I(Requires a single-acting,Required
combustion air from withinlisted barometric damper if vent
the building.)length exceeds Table 5A.)
Direct Venting (OutsideVertical Direct VentingCategory IAL29-4C Stainless SteelPVC, ABS, CPVC**
combustion air thru sealedVent Pipe**
pipe to boiler intake.)Horizontal DirectCategory IIIAL29-4C Stainless SteelPVC, ABS, CPVC**
Ducted Air*** (UsingType B Vent Pipe*
combustion air from outsideVertical Natural DraftCategory I(Requires a single-acting,PVC, ABS, CPVC,
the building ductedlisted barometric damper if ventGalvanized Metal Duct
to boiler intake.)length exceeds Table 5A.)Pipe**
NOTES: * A standard list type B vent terminal as supplied by the vent pipe manufacturer may be used.
** Vent cap/vent terminations and combustion air intake terminations must be furnished by the boiler manufacturer in accordance with
CSA requirements.
windy conditions and premature boiler failure.
*** Cannot be used in rooms with negative pressure.
No substitutions; unapproved substitutions may/will result in dangerous conditions, nuisance lockouts during
Type B Vent Pipe*None
FLUE BOX INSTALLATION
This boiler can be vented and/or bring in fresh air through the
rear of the cabinet with the use of the FLUE BOX and vent adaptor.
Any of the previous venting configurations can be installed with
rear connections.
FIGURE 16. STANDARD INSTALLATION
FIGURE 17. REAR VENT INSTALLATION
To change the unit to rear exhaust:
1. REFER TO THE PSD PARTS LIST, PART NO. 212131-000, AND
ORDER THE "FLUE BOX INSULATION" (211909-007 FOR THE
-300 MODEL; 211909-008 FOR THE 400 & 500 MODEL/
211909-009 FOR THE 650 & 750 MODEL). THIS PART MUST
BE IN HAND BEFORE PROCEEDING TO STEP 2.
2. Remove the vent collar, vent collar gasket, jacket top (from
the top) and remove the cover plate and cover plate gasket
(from the rear).
3. Remove as thoroughly as possible the fluebox insulation on
top of the fluebox. REPLACE this part by applying hightemperature spray adhesive on the newly ordered part and
adhering to the top of the fluebox.
4. Reinstall the jacket top and attach the cover plate (along with
its gasket).
5. CAREFULLY cut the exhaust hole through the exposed fluebox
insulation on the back of the fluebox. Dispose of the cut
round piece of insulation.
6. Place the vent collar in alignment with the newly-cut exhaust
hole and drill screw holes through the fluebox, using the vent
collar as a template. Secure in place (along with its gasket)
with the existing sheet metal screws.
To change the unit to rear intake air:
1. The vent collar (for intake air) and the cover plate (for intake
air) must be switched. Insure all sheet metal screws are
back in place.
GAS CONNECTIONS
WARNING
THIS BOILER IS NOT INTENDED TO OPERATE AT GAS SUPPLY
PRESSURE OTHER THAN SHOWN ON THE RATING PLATE. A
LOCK-UP OR POSITIVE SHUT-OFF TYPE REGULATOR MUST
BE INSTALLED IN THE GAS SUPPLY LINE. EXPOSURE TO
HIGHER GAS SUPPLY PRESSURE MAY 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 SUPPLY SYSTEM, THE GAS VALVES
MUST BE CHECKED FOR SAFE OPERATION. MAKE SURE THAT
THE OUTSIDE VENTS ON THE SUPPLY REGULATORS AND
THE SAFETY VENT VALVES ARE PROTECTED AGAINST
BLOCKAGE. THESE ARE PARTS OF THE GAS SUPPLY SYSTEM,
NOT THE BOILER. VENT BLOCKAGE MAY OCCUR DURING
ICE BUILD-UP OR SNOW STORMS.
WHEN LOCAL CODES REQUIRE A MAIN MANUAL SHUT-OFF
VALVE OUTSIDE THE BOILER JACKET, A SUITABLE MAIN
MANUAL SHUT-OFF VALVE MUST BE INSTALLED IN A LOCATION
COMPLYING WITH THOSE CODES.
IT IS IMPORTANT TO GUARD AGAINST GAS VALVE FOULING
FROM CONTAMINANTS IN THE GAS WAYS. SUCH FOULING
MAY CAUSE IMPROPER OPERATION, FIRE OR EXPLOSION. IF
COPPER SUPPLY 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.
11
FIGURE 18. VENT TERMINATIONS AND INSTALLATION CLEARANCES
TABLE 6. SINGLE UNIT INSTALLATION, SUGGESTED PIPE SIZE
0.60 Specific Gravity @ 0.5 In. W.C. Pressure Drop
3
1.53 Specific Gravity @ 0.60 In.W.C. Pressure Drop
TO TRAP ANY DIRT OR FOREIGN MATERIAL IN THE GAS
SUPPLY 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 (CURRENT EDITION).
To prevent damage, care must be taken not to apply too much
torque when attaching gas supply pipe to gas valve 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 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 ISOLATED FROM THE GAS SUPPLY
PIPING SYSTEM BY CLOSING ITS MAIN MANUAL GAS
SHUTOFF VALVE DURING ANY PRESSURE TESTING OF THE
GAS SUPPLY PIPING SYSTEM AT TEST PRESSURES EQUAL
TO OR MORE THAN 1/2 PSIG.
PURGING
Gas line purging is required with new piping or systems in which
air has entered.
CAUTION
PURGING SHOULD BE PERFORMED BY PERSONS
EXPERIENCED IN THIS TYPE OF GAS SERVICE TO 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 DEACTIVATED OR REMOVED.
BEFORE PLACING THE BOILER IN OPERATION, CHECK FOR
GAS LEAKAGE. Use soap and water solution or other material
acceptable for the purpose in locating gas leaks. DO NOT USE
MATCHES, CANDLES, FLAME OR OTHER SOURCES OF
IGNITION FOR THIS PURPOSE.
1.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 gas, consult your gas supplier.
2A. SIZING GAS SUPPLY LINE, (for single boiler installations),
see Table 6.
2B. SIZING GAS SUPPLY LINE, (for multiple installations of two
or more boilers), see Table 7.
Use Table 7, which is taken from ANSI booklet Z223.1,
NATIONAL
FUEL GAS CODE, or CAN/CSA-B149.1 (current edition) to size
iron pipe or equivalent gas supply line. Table 7 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).
Capacities in cubic feet per hour of 0.60 specific gravity gas for
different sizes and lengths of pipe are shown in Table 7. 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 (e.g., elbows, tees, and valves in gas supply line),
use a pipe size larger than specified to compensate for increased
pressure drop.
12
TABLE 7. SUGGESTED PIPE SIZE FOR MULTIPLE GAS APPLIANCES
NominalMaximum Capacity of Pipe in Cubic Feet of Gas per Hour for Gas Pressures
Iron Pipeof 14 in. W.C. (0.5 psi) or Less and a Pressure Drop of 0.5 in W.C. based on a 0.60 Specific Gravity Gas
Applications of the gravity factor converts the figures given in
Table 7 to capacities with another gas of different specific gravity.
Such application is accomplished by multiplying the capacities
given in Table 7 by the multipliers shown in Table 8.
HIGH ALTITUDE INSTALLATIONS
WARNING
INSTALLATIONS ABOVE 5,000 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.
These Genesis boilers are equipped with prejet orifices which
are self-regulating. This makes it unnecessary to replace these
prejet orifices for high altitude installations (up to 5,000 feet only.
Consult the factory for higher altitudes). These prejet orifices will
automatically compensate for higher elevations and adjust the
appliance's input rate accordingly, see Table 9.
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 2000 feet (600 m). For elevations above 2000
feet (600 m) ratings must be reduced by a rate of 4% for each
1000 feet (300 m) above sea level.
Example: A Genesis boiler is rated at 750,000 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
600,000 Btu/hr. (= 80% x 750,000 Btu/hr.) The input reduction is
achieved by the prejet orifices through self-regulation.
WIRING CONNECTIONS
ALL ELECTRICAL WORK MUST BE INSTALLED IN
ACCORDANCE WITH THE CURRENT EDITIONS OF THE
NATIONAL ELECTRICAL CODE NFPA 70/CANADIAN
ELECTRICAL CODE, CSA 22.1 AND MUST CONFORM TO LOCAL
REGULATIONS.
AN ELECTRICAL GROUND IS REQUIRED TO REDUCE RISK
OF ELECTRIC SHOCK OR POSSIBLE ELECTROCUTION.
the 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-C22.1 current edition.
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 dedicated and isolated line source that is:
120 volts, 60 Hertz, and 20 Amps.
The feedback contacts for a system controller (e.g. Honeywell
Aquastat) that is attached to the thermostat input, must operate
on the provided 24 VAC power.
Refer to the Connection Diagram and to the Schematic
Diagram.
National Electrical Code, ANSI/NFPA
Make
TABLE 9: ORIFICE SIZE FOR NATURAL AND PROPANE (LP) GASES (U.S. AND CANADIAN INSTALLATIONS)
(Drill size unless otherwise indicated.)
ModelRating Input BTUHNumber of BurnersNatural (3X)Propane (3X)