A. O. Smith GB-300 Installation Manual

0 (0)

COPPER BOILERS

FOR HYDRONIC HEATING AND HOT WATER SUPPLY

•Installation

•Operation

•Maintenance

•Limited Warranty

WARNING: If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

—Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

—WHAT TO DO IF YOU SMELL GAS:

•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.

CAUTION

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

Instruction Manual

GB/GW-300, 400, 500, 650, 750 SERIES 400, 401, 402, 403, 404, 405

2-STAGE UNITS

You Thankfor buying this

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 "LIMITED WARRANTY" ON PAGE 39

A DIVISION OFA. O. SMITH CORPORATION

MC BEE, SC., RENTON, WA.,

STRATFORD-ONTARIO, VELDHOVEN-THE NETHERLANDS www.hotwater.com

	PLACE THESE INSTRUCTIONS ADJACENT TO BOILER AND
PRINTED 0809	NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.	212130-002
PRINTED 0809		212130-002

FIGURE2.

FRONT

FIGURE1.

LEFTSIDE

							FIGURE		3.
							TOP
							TOP
TABLE 1A. BASIC GAS AND ELECTRICAL PARAMETERS
					MANIFOLD		MANIFOLD
MODEL	TYPEOF					PRESS.	PRESS.
GB/GW	GAS	VOLTS/HZ		AMPS	Inches W.C.		kPa
300	Natural	120/60		20		3.5	0.87
400	Natural	120/60		20		3.5	0.87
500	Natural	120/60		20		3.5	0.87
650	Natural	120/60		20		3.5	0.87
750	Natural	120/60		20		3.5	0.87
300	Propane	120/60		20		10.0	2.49
400	Propane	120/60		20		10.0	2.49
500	Propane	120/60		20		10.0	2.49
650	Propane	120/60		20		10.0	2.49
750	Propane	120/60		20		10.0	2.49
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)													FIGURE4.
													FIGURE4.
TABLE1B. ROUGH-INDIMENSIONS													REAR
TABLE1B. ROUGH-INDIMENSIONS

				Btu/hr.Input		KW Input	Exhaust			Water	Gas
	Btu/hr. Input		KW Input	Propane (LP)		Propane (LP)	Vent Size	Inlet Air		Connections	Piping	Width		Width		A	A	B	B	C	C
Model	Natural Gas		Natural Gas	Gas		Gas	(Inch)	(Inch)		Size (Inch)	(Inch)		(Inch)	(mm)	(inch)		(mm)	(Inch)	(mm)	(Inch)	mm
GB/GW 300	300,000		88	300,000		88	5	5		1 1/2	3/4	29 1/2		749	14 13/16		376	9	229	12	305
GB/GW 400	399,900		117	399,900		117	6	6		1 1/2	1	35 3/4		908	17 15/16		456	9	229	14 3/4	375
GB/GW 500	500,000		147	500,000		147	6	6		2	1	42		1067	21	1/16	535	9	229	14 3/4	375
GB/GW 650	650,000		190	650,000		190	8	8		2	1 1/4	51 3/8		1305	25 3/4		654	9	229	14 3/4	375
GB/GW 750	750,000		220	750,000		220	8	8		2	1 1/4	57 5/8		1464	28 7/8		733	9	229	17 1/4	438

FIGURE5.

REAR

FIGURE6.

TOP

FIGURE7.

LEFT SIDE

				FIGURE8.
TABLE 1C. OUTDOOR UNIT DIMENSIONS				FRONT
TABLE 1C. OUTDOOR UNIT DIMENSIONS

MODEL NUMBER	A	B	C	D	E	F	G1	G2
GBO/GWO-300	3	9 3/4	49	13 5/8	34 5/8	67.88	24 3/16	—
GBO/GWO-400	3	9 3/4	55 1/4	13 5/8	34 5/8	68.88	24 3/16	—
GBO/GWO-500	3	9 3/4	61 1/2	13 5/8	34 5/8	68.88	24 3/16	—
GBO/GWO-650	3	9 3/4	70 7/8	13 5/8	34 5/8	68.63	—	27 11/16
GBO/GWO-750	3	9 3/4	77 1/8	13 5/8	34 5/8	68.63	—	27 11/16

TABLE 2. PUMP PERFORMANCE

	Water	Flow Rate		Head Loss		Rise Temp.		Pipe Size	Pump
Model	Category	GPM	LPM	Feet	Meter	F	C	(Inch)	Taco Models*
GW-300	Normal	17	64	4.4	1.3	30	2.4	1 1/2"	0010
	Hard	25	95	9.5	2.9	20	5.3	1 1/2"	0012
GW-400	Normal	23	87	8.0	2.4	30	4.4	1 1/2"	0012
	Hard	34	129	6.0	1.8	20	3.3	2"	0012
GW-500	Normal	28	106	4.6	1.4	30	2.6	2"	0012
	Hard	42	159	9.1	2.8	20	5.1	2"	1911 (1/4 HP)
GW-650	Normal	37	140	6.2	1.9	30	3.4	2"	0012
	Hard	55	208	12.2	3.7	20	6.8	2"	1911 (1/3 HP)
GW-750	Normal	42	159	9.7	3.0	30	5.4	2"	1911 (1/4 HP)
	Hard	63	238	18.8	5.7	20	10.4	2"	1935 (1/3 HP)

Pressure drop includes the loss through 50' (15.2M) of pipe and normal fittings, when installed with storage tank.

WATER CATEGORY	GRAIN HARDNESS PER GAL.
NORMAL	1 THROUGH 15
HARD	OVER 15

*Taco Pumps shown. Equivalent Armstrong, Bell & Gossett or Grundfos are acceptable as long as the flow rates are maintained. Always ensure adequate support for pump and piping.

TABLE 3. RECOVERYCAPACITIES

TABLE4. HEATEXCHANGERPRESSUREDROP

TEMPERATURERISEANDPRESSUREDROP

	20 (oF) Rise		30 (oF) Rise		40 (oF) Rise		10 (oC) Rise		15 (oC) Rise		20 (oC) Rise
Model		PD-Ft.		PD-Ft.		PD-Ft.		PD-Meters		PD-Meters		PD-Meters
GB	Flow GPM	Head	Flow GPM	Head	Flow GPM	Head	Flow LPM	Head	Flow LPM	Head	Flow LPM	Head
300	25	1.3	17	0.6	13	0.4	95	0.38	64	0.19	49	0.12
400	34	2.2	23	0.9	17	0.6	129	0.67	87	0.28	64	0.20
500	42	3.4	28	1.8	21	0.9	159	1.03	106	0.54	79	0.29
650	55	3.5	37	2.0	27	1.8	208	1.07	140	0.61	102	0.56
750	63	8.3	42	4.3	32	2.1	238	2.53	159	1.31	121	0.64

FOREWORD

CAUTION

TEXT PRINTED OR OUTLINED IN RED CONTAINS INFORMATION RELATIVE TO YOUR SAFETY. PLEASE READ COMPLETELY BEFORE USING APPLIANCE.

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 TOAVOID POSSIBLE ERRORSAND 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.

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.

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."

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.

FIGURE9. BOILERONCOMBUSTIBLEFLOORBASE

Model	Combustible Floor Kit
(GB/GW)-300	210202-001
(GB/GW)-400	210202-002
(GB/GW)-500	210202-003
(GB/GW)-650	210202-004
(GB/GW)-750	210202-005

Two inch clearance is required from combustible construction to hot water pipes.

LEVELLING

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.

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.

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 OUTLETAND IT MUST NOT CONTAINANY VALVES BETWEEN THE BOILERAND THE RELIEF VALVE OR THE RELIEF VALVE AND THE DRAIN EXIT. IN ADDITION, THERE SHOULD NOT BE ANY RESTRICTIONS IN A DRAIN LINE NOR SHOULD IT BE ROUTED THROUGH AREAS WHERE FREEZING CONDITIONS MIGHT OCCUR. DO NOT THREAD OR CAP THE DRAIN LINE EXIT. RESTRICTING OR BLOCKING ADRAIN LINE WILL DEFEAT THE PURPOSE OF THE RELIEF VALVEAND MAY CREATEAN 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.

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.

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 INANAREAWHERE 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 HAZARDOUSARTICLES MUST NEVER BE PLACED ON OR ADJACENT TO THE BOILER.

OPEN CONTAINERS OF FLAMMABLE MATERIAL SHOULD NOT BE STORED OR USED IN THE SAME ROOM WITH THE BOILER.

If the boiler is installed above the level of heating system terminal units, a low water cutoff device must be installed in the boiler outlet at the time of installation.

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.

"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

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)

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 COMBUSTIONAND 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 COMBUSTIONAND VENTILATION AIR.

UNCONFINED SPACE

In buildings of conventional frame, brick or stone construction, unconfined spaces may provide adequate air for combustion.

If the unconfined space is within a building of tight construction (buildings using the following construction: weather stripping, heavy insulation, caulking, vapor barrier, etc.), air for combustion, ventilation, must be obtained from outdoors or spaces freely communicating with the outdoors. The installation instructions for confined spaces in tightly constructed buildings must be followed to ensure adequate air supply.

CONFINED SPACE

(a) U. S. INSTALLATIONS

When drawing combustion and dilution air from inside a conventionally constructed building to a confined space, such a space shall be provided with two permanent openings, ONE WITHIN 12 INCHES OF THE ENCLOSURE TOP AND ONE WITHIN 12 INCHES OF THE ENCLOSURE BOTTOM. Each opening shall have a free area of at least one square inch per 1000 Btuh of the total input of all appliances in the enclosure, but not less than 100 square inches.

If the confined space is within a building of tight construction, air for combustion, ventilation, and draft hood dilution must be obtained from outdoors. When directly communicating with the outdoors or communicating with the outdoors through vertical ducts, two permanent openings, located in the above manner, shall be provided. Each opening shall have a free area of not less than one square inch per 4000 Btuh of the total input of all appliances in the enclosure. If horizontal ducts are used, each opening shall have a free area of not less than one square inch per 2000 Btuh of the total input of all appliances in the enclosure.

(b) CANADIAN INSTALLATIONS

Ventilation of the space occupied by the boiler(s) shall be provided by an opening for ventilation air at the highest practical point communicating with outdoors. The total 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 mm2).

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 mm2/KW) up to and including 1,000,000 BTUH plus 1 square inch per 14,000 BTU in excess of 1,000,000 BTUH. This opening(s) shall be located at, or ducted to, a point neither more than 18" (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 CAUSEAIR TO BE DRAWN INTO THE ROOM THROUGH THE CHIMNEY, CAUSING POOR COMBUSTION. SOOTING MAY RESULT WITH AN INCREASED RISK OFASPHYXIATION.

VENTING THE BOILER

This boiler is approved to be vented as a Category I, Category III (horizontal venting), or a Direct Vent appliance. The Horizontal and Direct Venting options require a special vent kit.

TABLE 5.

Horizontal Vent or
Horizontal Direct Vent Kit	Model Number
210320-001	G(W,B) 300
210320-002	G(W,B) 400
210320-002	G(W,B) 500
210320-003	G(W,B) 650
210320-003	G(W,B) 750

Vertical Direct Vent Kit	Model Number
210317-001	G(W,B) 300
210317-002	G(W,B) 400
210317-002	G(W,B) 500
210317-003	G(W,B) 650
210317-003	G(W,B) 750

CAUTION

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 TOAVOID CHOKED COMBUSTION OR RECIRCULATION OF FLUE GASES. SUCH CONDITIONS CAUSE SOOTING OR RISKS OF FIREANDASPHYXIATION.

STANDARD (VERTICAL) VENTING, CATEGORY I

THIS BOILER MAYBE VENTEDACCORDING TOTABLE 5AAND 5C (ALSOSEEFIGURE6). ATLEASTTYPEBVENTINGMUSTBEUSED WITHTHE STANDARD VENTING OPTION (thru-the-roof) USINGTHE NATIONAL FUEL GAS CODE VENT TABLES.* TYPE B VENT PIPE CANNOT BE USED IF THE BOILER IS VENTED HORIZONTALLY (SEE PAGES 10AND 11). ALLLOCALUTILITY, 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 Number	Vent Connector
G(W,B) 300	5"
G(W,B) 400	6"
G(W,B) 500	6"
G(W,B) 650	8"
G(W,B) 750	8"

*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.

FIGURE 10. SINGLE PIPE VERTICALTERMINATION

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.c. and a maximum draft of -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.

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.

SINGLE PIPE HORIZONTALVENTING

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 HORIZONTALTERMINATION

TABLE 5A. SINGLE PIPE HORIZONTALAND VERTICALVENTING

MODEL	EXHAUSTVENT*
GB/GW-300	110'
GB/GW-400	50'
GB/GW-500	50'
GB/GW-650	50'
GB/GW-750	50'

*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.

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 HORIZONTALAND VERTICAL VENTING

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). 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 HORIZONTALAND VERTICALVENTING

MODEL	INTAKE*	EXHAUST*
GB/GW-300	60'	60'
GB/GW-400	35'	35'
GB/GW-500	35'	35'
GB/GW-650	35'	35'
GB/GW-750	35'	35'

*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 exhaust and intake air termination must be a minimum of 12 inches above anticipated snow or grade level which ever is higher, see Figure 14.

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.