A O Smith 200 User Manual

COPPER BOILERS FOR

HYDRONIC HEATING AND

HOT WATER SUPPLY

• Installation

Instruction Manual

• Operation

GB/GW MODELS:

1000, 1300, 1500, 1850, 2100, 2500

SERIES 200, 201

• Maintenance

• Limited Warranty

CAUTION

TEXT PRINTED OR OUTLINED IN RED CONTAINS

INFORMATION RELATIVE TO YOUR SAFETY.

PLEASE READ THOROUGHLY BEFORE INSTALLING

AND USING THIS APPLIANCE.

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.

for buying this cost

Thank Y

efficient, high recovery unit from

A. O. Smith Water Products Co.

You should thoroughly read and understand this

manual before installation and/or operation of this

boiler. Please pay particular attention to the

important safety and operating instructions as well

as the WARNINGS and CAUTIONS.

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:

CONTENTS

PAGE

•

Extinguish any open flame.

ROUGH-IN DIMENSIONS/CAPACITIES ............. 2 - 3

FOREWORD ..................................................... 4 - 5

FEATURES/CONTROLS ................................... 5 - 6

INSTALLATION INSTRUCTIONS ................... 6 - 22

VENTING ....................................................... 8 - 14

SYSTEM INSTALLATION ..............................15 - 19

HYDRONIC INSTALLATION ..........................15 - 17

HOT WATER SUPPLY INSTALLATION .........17 - 19

GAS CONNECTIONS ....................................20 - 21

OPERATION ................................................ 22 - 23

LIGHTINGANDOPERATING .........................24 - 25

CONTROL SYSTEM .................................... 26 - 31

PREVENTATIVE MAINTENANCE ................ 31 - 33

TROUBLE SHOOTING ..................................33 - 34

LIMITED WARRANTY .......................................... 35

WIRING DIAGRAM/SCHEMATIC .................. 36 - 37

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.

•

ADIVISION OFA. O. SMITH CORPORATION

ELPASO, TX., MC BEE, SC., RENTON, WA.,

STRATFORD-ONTARIO, VELDHOVEN-THE NETHERLANDS

www.hotwater.com

PLACE THESE INSTRUCTIONS ADJACENT TO BOILER AND

NOTIFYOWNERTOKEEPFORFUTUREREFERENCE.

PRINTED IN U.S.A. 2526 0501

PART NO. 211257-000 REV. 0

TABLE 3: RECOVERY CAPACITIES

Input Rating

Temperature Rise - Degrees °F (°C)

50°F 60°F 70°F 80°F 90°F 100°F 110°F 120°F 130°F

per Hr. (22.2°) (27.7°) (33.3°) (38.8°) (44.4°) (50°) (55.5°) (61.1°) (66.7°) (72.2°)

Gal/Liter 40°F

MODEL

BTU/Hr. (kW)

GW - 1000

990,000 (290.1)

LPH

GPH

LPH

GPH

LPH

GPH

LPH

GPH

LPH

GPH

LPH

GPH

9526 7620 6350 5443 4763 4234 3810 3462 3175 2930

2520 2016 1680 1440 1260 1120 1008 916 840 775

GW - 1300

GW - 1500

GW - 1850

GW - 2100

GW - 2500

1,300,000 (380.9)

1,500,000 (439.5)

1,850,000 (542.0)

2,100,000 (615.3)

2,490,000 (729.6)

12508 10006 8339 7148 6256 5560 5005 4547 4169 3848

3309 2647 2206 1891 1655 1471 1324 1203 1103 1018

14432 11548 9620 8248 7216 6415 5772 5247 4812 4442

3818 3055 2545 2182 1909 1697 1527 1388 1273 1175

17800 14239 11865 10172 8902 7912 7122 6471 5935 5477

4709 3767 3139 2691 2355 2093 1884 1712 1570 1449

20204 16163 13472 11548 10104 8981 8082 7348 6736 6218

5345 4276 3564 3055 2673 2376 2138 1944 1782 1645

23958 19168 15971 13691 11979 10648 9582 8713 7987 7371

6338 5071 4225 3622 3169 2817 2535 2305 2113 1950

TABLE 4: HEAT EXCHANGER PRESSURE DROP

GB Models-Flow, Head Loss and Temperature Rise

20 Deg. F Rise

30 Deg. F Rise

40 Deg. F Rise

Maximum Flow Rate

GPM PD-FT Deg. F

Minimum Flow Rate

GPM

PD-FT

Head

GPM

PD-FT

Head

GPM

PD-FT

Head

GPM

PD-FT

Head

Deg. F

MODEL

Head

12.2

Rise

GB - 1000

83.16

109.2

126

154

n/a

5.1

7.2

55.4

72.8

2.7

4.2

41.6

54.6

1.5

3.2

4.3

6.4

8.3

11.6

154

1.5

3.2

4.3

6.4

8.3

11.6

GB - 1300

GB - 1500

GB - 1850

GB - 2100

GB - 2500

14.5

16.3

18.5

21.3

23.2

10.1

18.5

n/a

6.3

103.6

117.6

139.4

10.1

14.5

18.5

77.7

88.2

104.6

n/a

105

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

(15.2 m) of normal pipe fittings.

PRECAUTIONS

FOREWORD

IF THE UNIT IS EXPOSED TO THE FOLLOWING, DO NOT

OPERATE UNTIL ALL CORRECTIVE STEPS HAVE BEEN MADE

BY A QUALIFIED SERVICEMAN:

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.

1. EXPOSURE TO FIRE.

2. IF DAMAGED.

3. FIRING WITHOUT WATER.

4. SOOTING.

Detailed installation diagrams are found in this manual. These

diagrams will serve to provide the installer a reference for the

materials and methods of piping necessary. It is essential that all

water, gas piping and wiring be installed as shown on the diagrams.

You should thoroughly read and understand this manual before

installation and/or operation of this boiler.

IF THE BOILER HAS BEEN EXPOSED TO FLOODING, IT MUST BE

REPLACED.

LIQUID PETROLEUM MODELS

The factory warranty will be void if the boiler(s) have been improperly

installed or operated.

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.

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.

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

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/NFPA54 and the National made.

Electric Code, NFPA 70.

At times you may not be able to smell an LP gas leak. One cause

In Canada:

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.

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.

IF YOU EXPERIENCEAN OUT OF GAS SITUATION, DO NOT TRY

TO RELIGHT APPLIANCES YOURSELF. Call your local service

agent. Only trained LP professionals should conduct the required

safety checks in accordance with industry standards.

GROUNDING INSTRUCTIONS

This boiler must be grounded in accordance with the National

Electrical Code and/or local codes. Boiler is polarity sensitive,

correct wiring is imperative for proper operation.

HIGHALTITUDE INSTALLATION

WARNING

INSTALLATIONS ABOVE 4,500 FEET REQUIRE REPLACEMENT

OF THE BURNER ORIFICES IN ACCORDANCE WITH THE

NATIONAL FUEL GAS CODE (ANSI/NFPA 54). FAILURE TO

REPLACE THE ORIFICES WILL RESULT IN IMPROPER AND

INEFFICIENT OPERATION OF THE APPLIANCE, PRODUCING

CARBON MONOXIDE GAS IN EXCESS OF SAFE LIMITS, WHICH

COULD RESULT IN SERIOUS PERSONAL INJURY OR DEATH.

This boiler must be connected to a grounded metal, permanent

wiring system, or an equipment grounding conductor must be run

with the circuit conductors and connected to the equipment

grounding terminal or lead on the boiler.

WARNING

YOUR BOILER IS NOT DESIGNED TO OPERATE WITHABOILER

INLET WATER TEMPERATURE OF LESS THAN 120°F (38°C).

COLDER INLET WATER TEMPERATURE WILL RESULT IN

SIGNIFICANT CONDENSATION DEVELOPING ON THE HEAT

EXCHANGER. THIS SITUATION CAN CAUSE A CORROSIVE

ENVIRONMENT FOR THE HEAT EXCHANGER, BURNERS AND

VENTING RESULTING IN PREMATURE DAMAGE, WHICH COULD

RESULT IN SERIOUS PERSONAL INJURY OR DEATH.

GENESIS BOILERS ARE EQUIPPED WITH SELF-REGULATING

PREJET ORIFICES WHICHAUTOMATICALLY COMPENSATE FOR

HIGHER ELEVATIONS AND ADJUST THE APPLIANCE'S INPUT

RATEACCORDINGLY, MAKING IT UNNECESSARY TO REPLACE

ORIFICES FOR HIGH ALTITUDE (UP TO 4,500 FEET ONLY.

CONSULT THE FACTORY FOR HIGHERALTITUDES.)

FOR SYSTEMS THAT USE LARGE VOLUMES OF COLD WATER Some utility companies derate their gas for altitude. You should

OR SYSTEMS UTILIZING HEAVY WATER DRAWS, CONDENSATION

CAN BE PREVENTED BY USINGABYPASS LOOP.

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.

CORRECT GAS

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.

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.

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.

FLAME SENSOR

The flame sensor acts to prove the flame has carried over from the

(= 80% x 1,300,000 Btu/hr.) The input reduction is achieved by 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 restart the boiler.

prejet orifices through self-regulation.

FEATURES/CONTROLS

WATER FLOW SWITCH

MULTI-STAGE FIRINGAND CONTROL SYSTEM

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.

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.

LIMIT CONTROLS

CAUTION

LIMIT CONTROLS ARE SAFETY DEVICES AND ARE NOT TO BE

USEDASATHERMOSTAT.

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.

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.

DIP SWITCH CONFIGURATION TABLE

SW1 OFF

SELECTION:

EITHER 3 OR 4 STAGE SYSTEM

EITHER 3 OR 1

WHETHER SYSTEM IS IRI OR

STANDARD

INLET OR TANKAS

CONTROLLINGPROBE

WHETHEREXTERNAL

3 STAGE

3 TRIALS

NOIRI

4 STAGE

1 TRIAL

IRI

If lockout occurs, manually push the ENTER/RESET

push-button on the display panel to restart the boiler.

GAS VALVE GAS VALVE

INLET TANK

ON/OFF SWITCH

NO EXTERNAL EXTERNAL

THERMOSTAT THERMOSTAT THERMOSTATIS USED

OUTLET 210°F OUTLET 240°F OUTLETMAXIMUMTEMPERATURE

The ON/OFF switch is a single-pole, single-throw rocker switch.

The switch provides 120VAC from the line source to the boiler.

190°F

220°F

MAX. SET-POINTTEMPERATURE

EITHER °F OR °C FOR DISPLAYED

TEMPERATURE

DEGREES°F DEGREES°C

COMBUSTION AIR BLOWER

Provides air for combustion process. The blower settings are

adjustable through the use of the air shutter, however, blowers are

set at the factory and should not need adjustment.

Figure 2. Summary of Dip Switch Options.

DIFFERENTIAL PRESSURE SWITCH

TANK PROBE

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.

FOR HOT WATER SUPPLY SYSTEMS (GW models),Atank 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).

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.

FOR HOT WATER HEATING SYSTEMS (GB models) Due to the

many various types of systems and operating conditions, a tank

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.

If any safety relief valve is replaced, the replacement valve must

comply with the latest version of the ASME Boiler and Pressure

Vessel Code, Section IV (HEATING BOILERS). Select a relief valve

with a discharge rating NOT less than the boiler input, and a set

pressure NOT exceeding the working pressure of any component

in the system.

The storage tank temperature and pressure relief valve must

comply with the applicable construction provisions of the Standard

for Relief Valves and Automatic Gas Shut-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.

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.

CIRCULATING PUMP

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.

The pump flow rate should not exceed the maximum

recommended flow rate, see table 4.

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.

FOR HOT WATER SUPPLY SYSTEMS (GW models), ordered with

the circulator as an integral part of the boiler; the pump has been

lubricated at the factory, and future lubrication should be in

accordance with the motor manufacturer's instructions provided

as supplement to this manual.

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.

FOR HOT WATER HEATING SYSTEMS (GB models or GW models

ordered without circulator), the circulator is NOT provided and

must be field-installed.

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.

LOW WATER CUTOFF (Not Supplied)

If low water protection is required by the authorities having

jurisdiction, a low water cutoff switch should be installed

next to the boiler in the outlet water line as shown in

"HYDRONIC INSTALLATION" section. The switch should receive

periodic (every six months) inspection to assure proper operation.

A low water cutoff device of the float type should be flushed every six

months.

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.

DRAIN VALVE (Not Supplied)

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.

Additional drain valves must be obtained and installed on each

boiler and tank for draining purposes.

SAFETY RELIEF VALVES

Your local code authority may have other specific relief valve

requirements not covered below.

INSTALLATION INSTRUCTIONS

WARNING

THE PURPOSE OF A SAFETY RELIEF VALVE IS TO AVOID

EXCESSIVE PRESSURE WHICH MAY CAUSE TANK EXPLOSION,

SYSTEM OR BOILER DAMAGE.

REQUIRED ABILITY

INSTALLATION OR SERVICE OF THIS BOILER REQUIRESABILITY

EQUIVALENT TO THAT OF A LICENSED TRADESMAN IN THE

FIELD INVOLVED. PLUMBING, AIR SUPPLY, VENTING, GAS

SUPPLY AND ELECTRICAL WORK ARE REQUIRED.

TOAVOID WATER DAMAGEADRAIN LINE MUST BE CONNECTED

TOASAFETY RELIEF VALVE TO DIRECT DISCHARGE TOASAFE

LOCATION. A DRAIN LINE MUST NOT BE REDUCED FROM THE

SIZE OF THE VALVE OUTLET AND IT MUST NOT CONTAIN ANY

VALVES BETWEEN THE BOILERAND THE RELIEF VALVE OR THE

RELIEF VALVE AND THE DRAIN EXIT. IN ADDITION, THERE

SHOULD NOT BE ANY RESTRICTIONS IN A DRAIN LINE NOR

SHOULD IT BE ROUTED THROUGH AREAS WHERE FREEZING

CONDITIONS MIGHT OCCUR. DO NOT THREAD OR CAP THE

DRAIN LINE EXIT. RESTRICTING OR BLOCKING A DRAIN LINE

WILL DEFEAT THE PURPOSE OF THE RELIEF VALVE AND MAY

CREATEAN UNSAFE CONDITION. INSTALLADRAIN LINE WITH

A DOWNWARD SLOPE SUCH THAT IT NATURALLY DRAINS

ITSELF.

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 THEADJACENTAREAOR TO LOWER

FLOORS OF THE STRUCTURE.

INSTALLATION CLEARANCES

Sufficient area should be provided at the front and sides of the

unit for proper servicing. For ease of service, minimum

clearances of 24" (61.0 cm) in the front and 18" (46.0 cm) on

the sides are recommended. It is important that the minimum

clearances be observed to allow service to the control box and

other controls. Observing proper clearances will allow service

to be performed without movement or removal of the boiler from

its installed location. Failure to observe minimum clearances

may require removal of the boiler in order to service such items as

the heat exchanger and burners. In a utility room installation, the

door shall be wide enough to allow the boiler to enter or to permit

the replacement of another appliance.

WHEN SUCH LOCATIONS CANNOT BE AVOIDED, A SUITABLE

DRAIN PAN SHOULD BE INSTALLED UNDER THE BOILER. Such

pans should be fabricated with sides at least 2-1/2" (6.5 cm) deep,

with length and width at least 2" (5.1 cm) greater than the dimensions

of the boiler and must be piped to an adequate drain. The pan

must not restrict combustion air flow.

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.

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 VAPORSARE

HEAVYAND TRAVELALONG THE FLOOR AND MAY BE IGNITED

BY THE IGNITER OR MAIN BURNER FLAMES CAUSING FIRE OR

EXPLOSION. SOME LOCALCODES PERMIT OPERATION OF GAS

APPLIANCES IF INSTALLED 18 INCHES (46.0 CM) OR MORE

ABOVE THE FLOOR. THIS MAY REDUCE THE RISK IF LOCATION

IN SUCHAN AREA CANNOT BE AVOIDED.

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.

FLAMMABLE ITEMS, PRESSURIZED CONTAINERS OR ANY

OTHER POTENTIAL FIRE HAZARDOUS ARTICLES MUST NEVER

BE PLACED ON OR ADJACENT TO THE BOILER.

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.

OPEN CONTAINERS OF FLAMMABLE MATERIAL SHOULD NOT

BE STORED OR USED IN THE SAME ROOM WITH THE BOILER.

If the boiler is installed above the level of heating system terminal

units, a low water cutoff device must be installed in the boiler outlet

at the time of installation.

For installation locations with elevations above 4,500 feet

(1350 m), consult the factory.

WARNING

UNDER NO CIRCUMSTANCES SHOULD THE EQUIPMENT ROOM

WHERE THE BOILER IS INSTALLED EVER BE UNDER NEGATIVE

PRESSURE. PARTICULAR CARE MUST BE TAKEN WHEN

EXHAUST FANS, COMPRESSORS,AIR HANDLING EQUIPMENT,

ETC., MAY INTERFERE WITH THE COMBUSTION AND

VENTILATIONAIR SUPPLIES OF THIS BOILER.

MODEL

COMBUSTIBLE FLOOR KIT NO.

211093

(GB/GW)-1000

(GB/GW)-1300

(GB/GW)-1500

(GB/GW)-1850

(GB/GW)-2100

(GB/GW)-2500

211093-1

211093-2

CHEMICAL VAPOR CORROSION

211093-3

211093-4

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.

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.

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.

AIR REQUIREMENTS

WARNING

FOR SAFE OPERATION, AN AMPLE SUPPLY OF AIR MUST BE

PROVIDED FOR PROPER COMBUSTION AND VENTILATION IN sufficient openings for air must be provided in the walls.

ACCORDANCE WITH THE NATIONAL FUEL GAS CODE, ANSI

Z223.1 OR CAN/CSA-B149.1 AND .2 (LATEST EDITIONS) OR

APPLICABLE PROVISIONS OF THE LOCAL BUILDING CODES.

AN INSUFFICIENT SUPPLY OF AIR MAY RESULT IN A YELLOW,

LUMINOUS BURNER FLAME, CARBONING OR SOOTING OF THE

FINNED HEAT EXCHANGER, OR CREATE A RISK OF

ASPHYXIATION. DO NOT OBSTRUCT THE FLOW OF

COMBUSTIONAND VENTILATIONAIR.

UNDERSIZED OPENINGS WILL CAUSE AIR TO BE DRAWN INTO

THE ROOM THROUGH THE CHIMNEY, CAUSING POOR

COMBUSTION. SOOTING MAY RESULT WITH AN INCREASED

RISK OFASPHYXIATION.

VENTING

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

(horizontal venting), or a Direct Vent appliance. The Horizontal and

Direct Venting options require a special vent kit.

UNCONFINED SPACE

In buildings of conventional frame, brick or stone construction,

unconfined spaces may provide adequate air for combustion.

TABLE 6: DIRECT VENT KITS

Horiz. or Horiz. Direct Vent Kit No.

211090

Model Number

G(W,B) 1000

G(W,B) 1300

G(W,B) 1500

G(W,B) 1850

G(W,B) 2100

G(W,B) 2500

Model Number

G(W,B) 1000

G(W,B) 1300

G(W,B) 1500

G(W,B) 1850

G(W,B) 2100

G(W,B) 2500

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.

211090-1

211090-4

211090-2

211090-3

Vertical Direct Vent Kit No.

211089

CONFINED SPACE

211089-1

211089-4

211089-2

(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.

211089-3

CAUTION

WHEN VENTING THE GENESIS BOILER THROUGH AN

OVERSIZED CHIMNEY (INCLUDING MASONRY CHIMNEYS),

ADDITIONAL CARE MUST BE EXERCISED TO ASSURE PROPER

DRAFT. FOR PROPER OPERATION,AMINIMUM DRAFT OF -0.02"

W.C.ANDAMAXIMUM DRAFTOF -0.04" W.C. MUSTBE MAINTAINED.

IN INSTANCES OF EXCESSIVE DRAFT,ABAROMETRIC DAMPER

MAY BE REQUIRED TO ASSIST IN MAINTAINING THE PROPER

DRAFT. DRAFT SHOULD BE MEASURED 2 FEET (0.6 M)ABOVE

THE BOILER VENT COLLAR.

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.

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 FIREANDASPHYXIATION.

(b) CANADIAN INSTALLATIONS

CONNECTING BOILER TO A COMMON VENT

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).

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.

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" (46.0 cm) nor less than 6 inches (15.2 cm)

above the floor level.

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.

Where power vented equipment is used in the same room as the

boiler, sufficient air openings must be supplied. UNDERSIZED 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.

OPENINGS MAY RESULT IN INSUFFICIENT AIR FOR

COMBUSTION.

Where an exhaust fan is installed in the same room with a boiler,

LOCATION REQUIREMENTS (INTAKE/EXHAUST)

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.

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.

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, 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.

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.

10.The mid point of the termination elbow must be a minimum of

12 inches (30.5 cm) from the exterior wall.

CAUTION

Direct venting into dead air spaces such as alleys, atriums and

inside corners can cause recirculation of flue gases.

Recirculation of flue gases will cause sooting, premature failure

of the heat exchanger and icing of the combustion air intake

during severe cold weather. To prevent the recirculation of flue

gases, maintain as much distance as possible between the

combustion air intake and the exhaust vent terminal.

Figure 4. Vent Termination Installation Clearances

STANDARD VENT - VERTICAL (CATEGORY I)

IMPORTANT!

VENT PRESSURE MUST BE MAINTAINED

BETWEEN -0.02" W.C. AND -0.04" W.C. AT 24"

(61.0 cm) ABOVE BOILER COLLAR.

Figure 5.

TABLE 7. STANDARD VERTICAL VENTING (CATEGORY I)

APPLIANCE

CATEGORY

CERTIFIED

VENTING

MATERIAL

EXHAUST

VENT SIZE

(INCHES)

MAXIMUM

VENT LENGTH

(FEET)

MODEL

I000

STAINLESS

STEEL

III

70' (21.3 m)

10”(25.4 cm)

12" (30.5 cm)

1300

1500

STAINLESS

STEEL

1850

2100

STAINLESS

STEEL

14"(35.6 cm)

16" (40.6 cm)

STAINLESS

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.

• 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.

DIRECT VENT - VERTICAL (CATEGORY I)

Figure 7.

TABLE 9. DIRECT VENT (VERTICALEXHAUST CONFIGURATIONS)

APPLIANCE

CERTIFIED

EXHAUST VENT

MAXIMUM

AIRINTAKE

MATERIAL

AIR INLET

SIZE (INCHES)

MAXIMUM

AIRINTAKE

MODEL CATEGORY EXHAUST VENT SIZE (INCHES) EXHAUST VENT

MATERIAL

LENGTH(FEET)

GAL. STEEL

PVC, ABS OR

CPVC

TYPE B OR

10"

35'

I000

EQUIVALENT

(25.4 cm)

(10.7 m)

(20.3 cm)

(10.7 m)

GAL.STEEL

PVC, ABS CR

CPVC

TYPE B OR

1300

1500

12"

(30.5 cm)

35'

(10.7 m)

10"

(25.4 cm)

35'

(10.7 m)

EQUIVALENT

GAL. STEEL

PVC, ABS OR

CPVC

TYPE B OR

14"

(35.6 cm)

20'

(6.1 m)

10"

(25.4 cm)

20'

(6.1 m)

1850

2100

2500

EQUIVALENT

GAL. STEEL

PVC, ABS OR

CPVC

TYPE B OR

14"

(35.6 cm)

20'

(6.1 m)

12"

(30.5 cm)

20'

(6.1 m)

EQUIVALENT

GAL. STEEL

PVC, ABS OR

CPVC

TYPE B OR

16"

(40.6 cm)

20'

(6.1 m)

12"

(30.5 cm)

20'

(6.1 m)

EQUIVALENT

• 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.

DIRECT VENT - HORIZONTAL (CATEGORY III)

Figure 8.

TABLE 10. DIRECT VENT (HORIZONTAL EXHAUST CONFIGURATIONS)

APPLIANCE

MODEL CATEGORY EXHAUST VENT

MATERIAL

CERTIFIED

VENT

SIZE

(INCHES)

MAXIMUM

VENTLENGTH

(FEET)

AIRINTAKE

MATERIAL

AIR INLET

SIZE

(INCHES)

MAXIMUM

AIRINTAKE

LENGTH(FEET)

GAL. STEEL

PVC, ABS OR

CPVC

10"

35'

STAINLESS

III

I000

(25.4 cm)

(SEALED)

(10.7 m)

(20.3 cm)

(10.7 m)

GAL.STEEL

PVC, ABS CR

CPVC

1300

1500

STAINLESS

(SEALED)

12"

(30.5 cm)

35'

(10.7 m)

10"

(25.4 cm)

35'

(10.7 m)

GAL. STEEL

PVC, ABS OR

CPVC

STAINLESS

(SEALED)

14"

(35.6 cm)

20'

(6.1 m)

10"

(25.4 cm)

20'

(6.1 m)

1850

2100

2500

GAL. STEEL

PVC, ABS OR

CPVC

14"

(35.6 cm)

20'

(6.1 m)

12"

(30.5 cm)

20'

(6.1 m)

STAINLESS

(SEALED)

III

GAL. STEEL

PVC, ABS OR

CPVC

16"

(40.6 cm)

20'

(6.1 m)

12"

(30.5 cm)

20'

(6.1 m)

STAINLESS

(SEALED)

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.

STANDARD (VERTICAL) VENTING, CATEGORYI

STANDARD (HORIZONTAL) VENTING, CATEGORY III

Vent sizing, installation and termination shall be in accordance

with the NATIONAL FUEL GAS CODE, ANSI Z223.1 OR

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.

THIS BOILER MAY BE VENTED ACCORDING TO TABLE 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 TABLES.* TYPE B VENT

PIPE CANNOT BE USED IF THE BOILER IS VENTED

HORIZONTALLY OR AS A DIRECT VENT (SEE PAGES 11

THROUGH 13). ALL LOCAL UTILITY, STATE/ PROVINCIAL,

REGULATIONS ON VENTING MUST BE FOLLOWED.

For Category III installations, It is important that the Installed vent

be airtight. Please insure that all joints are sealed properly during

installation.

VENT SIZING, INSTALLATION AND TERMINATION SHALL BE IN

ACCORDANCE WITH THE NATIONAL FUEL GAS CODE, ANSI

Z223.1 OR CAN/CSA-B149.1 and .2 (AND LATEST ADDENDA).*

DIRECT VENT VERTICALAND HORIZONTAL VENTING

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.

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-B149.1and .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.

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.

Table 11: VENT CONNECTION

HORIZONTALVENT INSTALLATION

VENT CONNECTOR

G(W,B) 1000

MODEL NUMBER

10" (25.4 cm)

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.

G(W,B) 1300

G(W,B) 1500

G(W,B) 1850

G(W,B) 2100

G(W,B) 2500

12" (30.5 cm)

14" (35.6 cm)

16" (40.6 cm)

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.

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.

Figure 9. Switching from Vertical to Horizontal Venting

CONVENTIONAL SPACE HEATING INSTALLATION

SYSTEM INSTALLATION

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.

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 Refer to table 4 showing flow rate vs. pressure drop and temperature

due to freezing is not covered by the warranty.

rise.

Good practice requires that all piping, etc., be properly supported.

Figure 10 shows a typical installation of the boiler.

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.

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.

HYDRONIC INSTALLATION

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).

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.

Table 12: INSTALLATION ITEMS

NO. SUGGESTED ITEMS FOR INSTALLATION

1. PAIR OF SHORT PIPE NIPPLES, PAIR OF BOILER

LOOP TEESAND BALL VALVE 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

INSTALLATIONAS 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.

5. PRESSURE GAUGE

6. LOW WATER CUTOFF (If Required By Local Code.)

7. SAFETY FLOW SWITCH (Factory-Installed)

8. RELIEF VALVE (Factory-Installed)

BYPASS BALANCING

9. BOILER INLET - OUTLET

10. SYSTEM SUPPLY TEMPERATURE THERMOMETER

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.

11. DRAIN or BLOW-DOWN VALVE

WATER SUPPLY 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.

AIR SEPARATOR

An air separator as shown in the piping diagram is reccommended

especially for modern commercial hydronic systems.

VENT VALVES

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.

It is recommended that automatic, loose key or screwdriver type

vent valves be installed at each convector or radiator.

SYSTEM HEADERS

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. A

MINIMUM PRESSURE OF 15 PSI (100 kPa) MUST BE MAINTAINED

ON THE BOILER AT ALL TIMES to avoid potential damage to the

boiler that may not be covered by the warranty.

Split systems with individual supply and return lines from the boiler

room should normally have this piping connected to supply and

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.

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.

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.

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.

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.

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.

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.

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 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.

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.

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.

SPACE HEATING APPLICATIONS

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

mandatory but offers smooth, efficient operation of a modern

system.

HARD WATER 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.

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.

WARNING

24 VAC System Controller (Optional)

LIME ACCUMULATION CAN REDUCE THE LIFE OF THE

EQUIPMENT, REDUCE EFFICIENCYAND WASTE FUEL. BOILER

FAILURE DUE TO LIME OR SCALE BUILDUP VOIDS THE

WARRANTY.

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 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 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.

INTERNALCONTAMINANTS

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.

TANK PROBE INSTALLATION 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.

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.

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.

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 Stop Leak or

other boiler compounds. The gas piping must also be leak tested.

THE WATER HEATER SHOULD BE LOCATED INANAREAWHERE

THE GENERAL PUBLIC DOES NOT HAVE ACCESS TO SET

TEMPERATURES.

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.

HOT WATER SUPPLY BOILER

INSTALLATION

EXPANSION TANK

WATER LINE CONNECTIONS

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

Where excessive heat exchanger condensation exists due to closed system is very important and is directly related to the total

continued low inlet water temperatures (below 120^oF), a bypass

balance loop must be installed (see figures 11 and 13).

water volume of the system. Refer to ASME or other reliable

specifications for sizing.

ONE GENESIS (MODEL GW) HOT WATER SUPPLY BOILER WITH HORIZONTAL TANK

PRESSURE RELIEF VALVE RATING SHOULD

NOT EXCEED PRESSURE CAPACITY OF ANY

COMPONENT IN THE SYSTEM.

IMPORTANT

SAFETY FLOW SWITCH PROTECTS THE

BOILER IN CASE OF WATER SERVICE

INTERRUPTION OR CIRCULATOR FAILURE.

INSTALL THERMAL EXPANSION

TANK ON COLD WATER

SUPPLY LINE, IF CHECK VALVE

OR PRESSURE REDUCING

VALVE IS USED IN SUPPLY.

PIPING SHOULD CONFORM TO LOCAL CODES.

•

PIPE TO OPEN DRAIN

FACTORY-INSTALLED ON UNIT

BALL VALVES ARE SHOWN FOR SERVICING

BOILER. HOWEVER, LOCAL CODES SHALL

GOVERN THEIR USAGE.

 SUPPLIED WITH UNIT



FIELD-INSTALLED

DANGER

TEMPERATURE SETTING SHOULD NOT EXCEED

SAFE USE TEMPERATURE AT FIXTURES.

SEE WATER TEMPERATURE CONTROL

WARNING ON PAGE 23. IF HIGHER PREHEAT

TEMPERATURESARE NECESSARYTO OBTAIN

ADEQUATE BOOSTER OUTPUT, ADD AN

ANTI-SCALD VALVE FOR HOT WATER

SUPPLIED TO FIXTURES.

WARNING

THE WATER MANIFOLD IS NOT DESIGNED TO

SUPPORT THE WEIGHT OF THE WATER PIPING

SYSTEM. AS ONALL BOILER INSTALLATIONS,

SPECIAL CARE MUST BE TAKEN TO ENSURE

PROPER SUPPORT.

TWO TEMPERATURE WATER

MIXING VALVE APPLICATION

MINIMUM

MODELS

PIPE SIZE

INCHES

CIRCULATING RETURN

LINE CONNECTIONS

GW-1000

THRU

2 1/2"

NPT

• TEMPERED WATER LOOP, IF USED,

CONNECT TO POINT R.

2500

• STOREDTEMPERATURE WATER LOOP,

IF USED, CONNECT TO ANY OPENING

NEAR BOTTOM OFTANK.

FACTORY PUMP SIZING

BASED ON 50 EQUIVALENT

FEET (15.2 m) OF PIPE.

Figure 11. Single boiler with horizontal tank.

Encase field-supplied wires

between tank probe and junction

box with 1/2" field supplied

conduit. "Pigtails" of field-

supplied 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. Tank probe installation.

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

FACTORY INSTALLED ON UNIT

 SUPPLIED WITH UNIT



FIELD-INSTALLED

DANGER

TEMPERATURE SETTING SHOULD NOT EXCEED SAFE USE

TEMPERATUREAT FIXTURES. SEE WATER TEMPERATURE

CONTROL WARNING ON PAGE 23. IF HIGHER PREHEAT TEM-

PERATURES ARE NECESSARY TO OBTAIN ADEQUATE

BOOSTER OUTPUT, ADD AN ANTI-SCALD VALVE FOR HOT

WATER SUPPLIED TO FIXTURES.

TWO TEMPERATURE WATER

MIXING VALVE APPLICATION

MINIMUM

PIPE SIZE

INCHES

MODELS

GW-1000

THRU

2 1/2"

NPT

2500

FACTORY PUMP SIZING BASED

ON 50 EQUIVALENT FEET

(15.2 m) OF PIPE.

INSTALL THERMAL EXPANSION

TANK ON COLD WATER SUPPLY

LINE, IF CHECK VALVE OR

PRESSURE REDUCING VALVE

IS USED IN SUPPLY.

CIRCULATING RETURN

LINE CONNECTIONS

• TEMPERED WATER LOOP, IF USED,

CONNECT TO POINT R.

• STOREDTEMPERATURE WATER LOOP,

IF USED, CONNECT TO ANY OPENING

NEAR BOTTOM OFTANK.

Figure 13. Single boiler with vertical tank.

threads of pipe joints. Do not apply compound to the first two

threads. Use compounds resistant to the action of liquefied

petroleum gases.

GAS CONNECTIONS

WARNING

THIS BOILER IS NOT INTENDED TO OPERATE AT GAS SUPPLY

PRESSURE OTHER THAN SHOWN ON THE RATING PLATE.

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 OFTHE 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 VALVESARE PROTECTEDAGAINST BLOCKAGE.

THESE ARE PARTS OF THE GAS SUPPLY SYSTEM, NOT THE

BOILER. VENT BLOCKAGE MAY OCCUR DURING ICE BUILD-UP

OR SNOW STORMS.

THE BOILER MUST BE ISOLATED FROM THE GAS SUPPLY PIPING

SYSTEM BY CLOSING ITS MAIN MANUALGAS SHUT-OFF VALVE

DURINGANY PRESSURE TESTING OF THE GAS SUPPLY 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

VALVE OUTSIDE THE BOILER JACKET,ASUITABLE MAIN MANUAL

SHUT-OFF VALVE MUST BE INSTALLED IN A LOCATION

COMPLYING WITH THOSE CODES.

2B. SIZING GAS SUPPLY LINE (For multiple installations of

two or more boilers). See tables 13 (Natural Gas) and 14

(Propane Gas).

TABLE 15. SINGLE UNIT INSTALLATION, SUGGESTED

PIPE SIZE

ITIS IMPORTANTTO GUARDAGAINSTGAS VALVE FOULING FROM

CONTAMINANTS IN THE GAS WAYS. SUCH FOULING MAY CAUSE

IMPROPER OPERATION, FIRE OR EXPLOSION. IF COPPER

SUPPLY LINESARE USED THEY MUST BEAPPROVED FOR GAS

SERVICE.

DISTANCE FROM METER

BTU INPUT 0-50' 51-100' 101-200' 201-300' 301-500'

990,000

1,300,000

1,500,000

2 1/2"

BEFORE ATTACHING THE GAS LINE BE SURE THAT ALL GAS

PIPE IS CLEAN ON THE INSIDE.

3 1/2"

1,850,000 2 1/2" 2 1/2"

TO TRAPANY DIRT OR FOREIGN MATERIALIN 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 RECOM-

MENDATIONS OF SERVING GAS SUPPLIERS. REFER TO

NATIONAL FUEL GAS CODE, ANSI Z223.1 OR CAN/CSA -B149.1

AND .2 (AND LATESTADDENDA).

2,100,000 2 1/2"

2,500,000 2 1/2"

3 1/2"

4 1/2"

Use tables 13 or 14, which are taken from ANSI booklet Z223.1,

NATIONAL FUELGAS 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.

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.

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.

Fittings and unions in the gas line must be metal to metal type.

Apply joint compounds (pipe dope) sparingly and only to the male

TABLE 16. Orifice Size for Natural and Propane (LP) Gases (U.S. and Canadian Installations)

[Drill size unless otherwise indicated.]

Rating Input

BTUH

990,000

1,300,000

1,500,000

1,850,000

2,100,000

2,490,000

Number of

Burners

Model

Natural (Holes)

0.111" (4X)

Propane (Holes)

0.071" (3X)

GB/GW 1000

GB/GW 1300

GB/GW 1500

GB/GW 1850

GB/GW 2100

GB/GW 2500

WIRING CONNECTIONS

OPERATION

ALLELECTRICAL WORK MUST BE INSTALLED INACCORDANCE

WITH THE MOST RECENT VERSION OF THE NATIONAL

ELECTRICAL CODE/CANADIAN ELECTRICAL CODE AND MUST

CONFORM TO LOCALREGULATIONS.

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.

AN ELECTRICAL GROUND IS REQUIRED TO REDUCE RISK OF

ELECTRIC SHOCK OR POSSIBLE ELECTROCUTION. Make the

ground connection to the wire provided in the electrical supply

junction box on the boiler.

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.

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 National Electrical Code, ANSI/NFPA

70 or CSA-C22.2 most recent edition.

GENERAL

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.

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.

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.

For heating boiler installations:

• Make sure that the boiler and system have been purged of air

and checked for leaks.

The Genesis Hot Water Supply Boiler must be connected to a single

phase line source that is:

Also be sure to check the gas piping for leaks before beginning the

initial firing of the boiler.

120 volts, 60 Hertz, and 30 Amps.

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.

FILLINGAND PURGING FOR HEATING

BOILER INSTALLATION

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.

Refer to the Schematic Diagram (Figure 19) and the Connection

Diagram (Figure 20) for wire connections.

Fuse Protection

2. Vent all high points in system to purge system of air.

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.

Provisions should be made to permit manual venting of radiators

or convectors.

FILLING FOR HOT WATER SUPPLYBOILER INSTALLATION

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.

Note: Four extra 3 amp fuses and one 5 amp fuse are supplied

with the boiler.

3. Fully open the cold water inlet pipe valve allowing the heater

and piping to be filled.

Recommended Replacement fuses:

4. Close the hot water faucet as water starts to flow.

5. The heater is ready to be operated.

3 Amp: Littlefuse automotive fuse PN 257003

5 Amp: Bussman Automotive fuse PN ATC5

2. CHECK THE INPUT. SEE SECTIONS "INLET GAS PRESSURE:"

AND SEE NATIONALFUEL GAS CODE,ANSI Z223.1 OR CAN/

CSA - B149.1 AND .2 (AND LATEST ADDENDA) FOR

PROCEDURES.

PURGING OF GAS LINE

Gas line purging is required with new piping or systems in which

air has entered.

DANGER

CAUTION

HOT WATER TEMPERATURES REQUIRED FOR AUTOMATIC

DISHWASHER AND LAUNDRY USE CAN CAUSE SCALD

BURNS RESULTING IN SERIOUS PERSONAL INJURY AND/OR

DEATH. THE TEMPERATUREATWHICH INJURY OCCURS VARIES

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 BATH WATER. NEVER LEAVEACHILD OR DISABLED

PERSON UNATTENDED IN A BATHTUB OR SHOWER.

PURGING SHOULD BE PERFORMED BY PERSONS

EXPERIENCED IN THIS TYPE OF GAS SERVICE TOAVOID 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. USEASOAPAND WATER SOLUTION OR OTHER

MATERIALACCEPTABLE FOR THE PURPOSE OF LOCATING GAS

LEAKS. DO NOT USE MATCHES, CANDLES, FLAME OR OTHER

SOURCES OF IGNITION FOR THIS PURPOSE.

THE WATER HEATER SHOULD BE LOCATED INANAREAWHERE

THE GENERAL PUBLIC DOES NOT HAVE ACCESS TO SET

TEMPERATURES.

WARNING

THE GAS VALVE MUST HAVE BEEN INTHE OFF POSITION FORAT

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 THAT GAS EVEN IF IT SEEMS WEAK, MAY INDICATE

PRESENCE OFACCUMULATED GAS SOMEPLACE IN THEAREA

WITH RISK OF FIRE OR EXPLOSION. SEE THE FRONT PAGE

FOR STEPS TO BE TAKEN.

INLET GAS PRESSURE

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.

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.

TABLE 17.

Inlet Gas Pressure

Max. Inlet Pressure (Inches W.C.)

Min. Inlet Pressure (Inches W.C.)

Nat. Gas

14.0

Prop. Gas

14.0

6.0

11.0

SETTING THE WATER HEATER TEMPERATURE AT 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.

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.

TABLE 18. Risk of Scalds

Temperature

Setting

Time to Produce 2nd & 3rd

Degree Burns on Adult Skin

Nearly instantaneous

About 1/2 second

IMPORTANT

Over 170°F (77°C)

160°F (71°C)

150°F (66°C)

140°F (60°C)

130°F (54°C)

120°F (49°C) or less

UNDER NO CIRCUMSTANCES SHALL THE GAS PRESSURE

MEASUREDATTHE BURNER MANIFOLD EXCEED THAT STATED

ON THE BOILER RATING PLATE. OVERFIRING WILL RESULT IN

DAMAGE TO THE BOILER, AS WELL AS INCREASED RISK OF

FIRE, SOOTINGANDASPHYXIATION.

About 1-1/2 seconds

Less than 5 seconds

About 30 seconds

More than 5 minutes

ADJUSTMENTS

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.

ON INITIALSTARTUP SOMEADJUSTMENTSARE NECESSARY.

1. CHECK MANIFOLD AND INLET GAS PRESSURES.

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, AFIRE OR

EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR

LOSS OF LIFE.

A. THIS APPLIANCE DOES NOT HAVE A PILOT. IT IS

C. USE ONLY YOUR HAND TO PUSH IN OR TURN THE GAS

CONTROL KNOB. NEVER USE TOOLS. IF THE KNOB WILL

NOT PUSH IN OR TURN BYHAND, DON’T TRYTO REPAIR

IT. CALLAQUALIFIED SERVICE TECHNICIAN. FORCE OR

ATTEMPTED REPAIR MAY RESULT IN A FIRE OR

EXPLOSION.

EQUIPPED WITH AN IGNITION DEVICE WHICH

AUTOMATICALLYLIGHTS THE BURNER. DO NOT TRYTO

LIGHT THE BURNER BY HAND.

B. BEFORELIGHTING:SMELLALLAROUNDTHEAPPLIANCE

AREAFORGAS. BESURETOSMELLNEXTTOTHEFLOOR

BECAUSE SOME GAS IS HEAVIER THANAIR AND WILL

SETTLE ON THE FLOOR.

D. DO NOT USE THISAPPLIANCE IFANY PART HAS BEEN

UNDER WATER. IMMEDIATELY CALL A QUALIFIED

SERVICE TECHNICIAN TO INSPECT THE APPLIANCE AND

TO REPLACEANYPART OF THE CONTROL SYSTEMAND

ANY GAS CONTROLWHICH HAS BEEN UNDER WATER.

WHAT TO 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

THEFIREDEPARTMENT.

E. DO NOT OPERATEAPPLIANCE UNLESS UNIT IS FILLED

WITH WATERAND WATER LINESARE FULLYOPEN.

OPERATING INSTRUCTIONS

STOP! READ THE SAFETYINFORMATION THE

NEXT STEP ABOVE ON THIS LABEL.

STOP ! FOLLOW “B” IN THE SAFETY INFORMATION

ABOVE ON THIS LABEL.

2. SET THE SYSTEM CONTROLLER TO THE LOWEST

SETTING.

IF YOU DON’T SMELLGAS, GO TO THE NEXT STEP.

8. TURN TOP KNOB OF GAS CONTROL COUNTER-

3. TURN OFF ALL ELECTRIC POWER TO APPLIANCE.

4. THIS APPLIANCE IS EQUIPPED WITH AN IGNITION

DEVICE WHICHAUTOMATICALLY LIGHTS THE BURNER.

DO NOT TRY TO LIGHT THE BURNER BY HAND.

5. REMOVE CONTROLACCESS PANEL.

CLOCKWISE

9. REPLACE CONTROLACCESS PANEL.

TO “ON” POSITION, (FIG. B).

10. TURN POWER SWITCH TO “ON” POSITION.

11. SET THE SYSTEM CONTROLLER TO DESIRED SETTING.

12. IF THEAPPLIANCE WILL NOT OPERATE, FOLLOW THE

INSTRUCTIONS“TOTURNOFFGASTOTHEAPPLIANCE”

AND CALL YOUR SERVICE TECHNICIAN OR GAS

SUPPLIER.

6. REFERTODIAGRAMSABOVE. TURNTOPKNOBOFGAS

CONTROL CLOCKWISE

TO “OFF” POSITION, (FIG. A).

7. WAIT FIVE (5) MINUTES TO CLEAR OUTANY GAS. THEN

SMELL FOR GAS, INCLUDING NEAR THE FLOOR. IF YOU

SMELL GAS,

TO TURN OFF GAS TO APPLIANCE

4. REFERTODIAGRAMSABOVE. TURNTOPKNOBOFGAS

CONTROL CLOCKWISE (TO “OFF” POSITION, (FIG. A).

5. REPLACE CONTROLACCESS PANEL.

1. SET THE SYSTEM CONTROLLER TO THE LOWEST

SETTING.

2. TURN POWER SWITCH ON APPLIANCE TO “OFF”

POSITION.

3. REMOVEACCESS PANELTO EXPOSE GAS CONTROL.

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.

C. USE ONLYYOUR HAND TO TURN THE MAIN MANUAL GAS

A. THISAPPLIANCE DOES NOT HAVEAPILOT. IT IS EQUIPPED

WITH AN IGNITION DEVICE WHICH AUTOMATICALLY

LIGHTSTHEBURNER. DONOTTRYTOLIGHTTHEBURNER

BYHAND.

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.

VALVE HANDLE. NEVER USE TOOLS. IF THE HANDLE WILL

NOT TURN BY HAND, DON’T TRY TO REPAIR IT. CALL A

QUALIFIED SERVICE TECHNICIAN. FORCE ORATTEMPTED

REPAIR MAYRESULT INAFIRE OR EXPLOSION.

D. DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN

UNDERWATER. IMMEDIATELYCALLAQUALIFIED SERVICE

TECHNICIAN TO INSPECT THE APPLIANCE AND TO

REPLACEANYPART OF THE CONTROL SYSTEMANDANY

GAS CONTROL WHICH HAS BEEN UNDER WATER.

WHAT TO 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.

E. DO NOT OPERATEAPPLIANCE UNLESS UNIT IS FILLED

WITH WATERAND WATER LINESARE FULLYOPEN.

•

IF YOU CANNOT REACH YOUR GAS SUPPLIER, CALL

THEFIREDEPARTMENT.

OPERATING INSTRUCTIONS

STOP!READTHESAFETYINFORMATIONABOVEON

THIS LABEL.

SET THE SYSTEM CONTROLLER TO THE LOWEST

SETTING.

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 VALVE TO “ON” POSITION,

(FIGURE “A”), THE VALVE IS “ON” WHEN THE HANDLE IS

PARALLEL TO THE GAS FLOW DIRECTION.

3. TURN POWER SWITCH ON APPLIANCE TO “OFF”

POSITION.

4. TURN MAIN MANUAL GAS VALVE TO “OFF” POSITION,

(FIGURE “B”). THE VALVE IS “OFF” WHEN THE HANDLE IS

PERPENDICULAR TO THE GAS FLOW DIRECTION.

5. THIS APPLIANCE IS EQUIPPED WITH AN IGNITION

DEVICE WHICHAUTOMATICALLY 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,

8. TURN POWER SWITCH TO “ON” POSITION.

9. SET THE SYSTEM CONTROLLER TO DESIRED SETTING.

10. IF THEAPPLIANCE WILL NOT OPERATE, FOLLOW THE

INSTRUCTIONS“TOTURNOFFGASTOTHEAPPLIANCE”

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 VALVE TO “OFF” POSITION, (FIGURE “B”). THE VALVE

IS “OFF” WHEN THE HANDLE IS PERPENDICULAR TO THE GAS FLOW DIRECTION.

These jumpers are pre-set at the factory and should only be

adjusted by a qualified service technician.

CONTROL SYSTEM

DESCRIPTION OF MULTI-STAGE FIRING SYSTEM

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

The Central Control Board (CCB) is responsible for staging the

Ignition Control Boards (ICB) and monitoring safety limit devices, "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.

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.)

DIA-SCAN II DISPLAYBOARD 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

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.)

DIP SWITCH CONFIGURATION TABLE

SW1 OFF

SELECTION:

EITHER 3 OR 4 STAGE SYSTEM

EITHER 3 OR 1

WHETHER SYSTEM IS IRI OR

STANDARD

INLET OR TANKAS

CONTROLLINGPROBE

WHETHEREXTERNAL

3 STAGE

3 TRIALS

NOIRI

4 STAGE

1 TRIAL

IRI

SW1

GAS VALVE GAS VALVE

INLET TANK

1 2 3 4 5 6 7 8

A B C D E F G H

NO EXTERNAL EXTERNAL

THERMOSTAT THERMOSTAT THERMOSTATIS USED

OUTLET 210°F OUTLET 240°F OUTLETMAXIMUMTEMPERATURE

190°F

220°F

MAX. SET-POINTTEMPERATURE

EITHER °F OR °C FOR DISPLAYED

TEMPERATURE

DEGREES°F DEGREES°C

Figure 14. Central Control Board's Dip Switch Configuration and Options

Figure 15. Ignition Control Board Jumper Settings

Green Status Lights

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.

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

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. Press-

ing the ENTER/RESET push-button will hold the display in the

indicated mode until the SELECT push-button is pressed.

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.)

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

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

•

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

Figure 16. Display Board

Outlet Probe

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

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.)

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.

To view the current programmed temperature set-point for the Out-

let Temperature probe:

Outlet:

Temperature shown is Outlet Water

Temperature.

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.

Set-Point**:

Indicated probe set-point is being

displayed.

Set-Point Differential:

Standby:

Shows differentials of each stage.

Indicates Set-Point is Satisfied. Boiler

in Idle State.

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.

*Defaults to tank probe temperature when Dip Switch "D" on

Central Control Board is Switched to the "ON" position.

(See Figure 14.)

Inlet Probe

**Shows set-point temperatures for Inlet/Tank or Outlet in

conjunction with yellow parameter lights. See temperature

probe section below.

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.)

TEMPERATURE 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.

To change or view the current programmed temperature set-point

for the Inlet Temperature probe value:

1. Press the SELECT push-button on the display board until both be established. To facilitate proper operation and maximize

the Set-Pt LED and Inlet Water Temperature LED (see appliance performance, each stage has a programmable

Figure 16) are illuminated.

2. The LED display will show the current set-point temperature.

operating switching differential or “hysteresis” about the set point.

This means a call for heat for a particular stage will become active

3. Press and hold the ADJUST push-button. The displayed when the water temperature measured at the controlling

temperature will either increase or decrease. To alternate temperature sensing probe drops to the set-point value minus the

between increasing or decreasing the temperature, release switching differential value. It is necessary to set three set-point

then press and hold the ADJUST push-button.

4. When the desired set-point temperature is reached, release burner will remain on until the water temperature measured at

the ADJUST push-button.

controlling probe reaches the stage set-point value. The switching

5. Press the ENTER/RESET push-button once, this enters the differential value is fully programmable from 0° F to 20°F (0°C to

differential values for three stage units and four for four stage. The

selected set-point temperature into controller memory.

6. The appliance will now control the temperature to the desired

set-point value.

11°C) using the push-button(s) located on the Display Board.

To change or view the current programmed switching differential:

7. For setting the stage differentials, see the section labeled

Procedure for Setting Stage 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.

NOTE: The boiler must complete a full cycle in order for the

new setting to take effect. If the unit is turned off prior 2. The LED display will show the current differential for stage

to a complete cycle the setting will be lost and the

previous setting will remain in effect.

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.

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 4. When the desired Set-Pt differential is reached, release the

located in the 24 VAC junction box at the rear of the unit. A 24 VAC

ADJUST push-button.

thermostat/aquastat can only be used as an "On/Off" switch for the 5. Press the ENTER/RESET push-button once, this enters 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.

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.

Tank Probe (Optional)

In addition to the Inlet and Outlet/ECO Probes, units can be 7. The appliance will now control temperature utilizing the

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.

desired differentials.

The tank Probe can be configured to control the staging of the unit. Example:

See Tank Probe Installation section on page 17 for additional Application: Hydronic Heating

information.

Procedure for Setting Tank Probe Temperature

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

If you have a GW hot water supply boiler, and have installed the tank staging of the unit. The controlling probe will be either the inlet or

probe, below are the instructions on how to adjust the water tank probe. (If the tank probe is used to regulate loop temperature

temperature set-point.

in hydronic applications (GB Models), make sure it is located on

the return side of the closed loop.) Use Dip Switch "D" on the

1. Press the SELECT push-button on the display board until both Central Control Board to make this selection. See Figure 14.

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.

Set the stage differentials using the procedure described in the

Procedure for Setting Stage Differential section of the document.

3. Press and hold the ADJUST push-button. The displayed Setting the control as described in the above example (5°F

temperature will either increase or decrease. To alternate differentials for each stage) will give the following stage set-points.

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.

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

7. For setting the stage differentials, see the section labeled

Procedure for Setting Stage Differential.

Procedure for Setting Stage Differential

Off Temperature: 170°F (77°C)

On Temperature: 165°F (74°C)

Once the system control and set-point temperature has been

entered, the switching differentials for the staging of the unit must

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 push-

button. Press the ENTER/RESET push-button to

successfully reset the cycle count. If the ENTER push-

button is not pressed, the reset function will not be saved and

the original cycle count will continue to increment on

each gas valve operation.

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.

6. The display will automatically return to illustrating the

controlling probe temperature after five (5) seconds.

To change or view the current programmed post-circulating time:

Appliance Operating Sequence

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.

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.

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:

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.

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.

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.

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

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

NOTE: Cleaning of main burners.

Shut off all gas and electricity to unit.

1. Remove main burners from unit.

drop out first followed by stages three, two and one. To achieve

maximum efficiency, stages will reignite if the system water

temperature drops below the stage Set Point minus the Set

Point Differential.

Note: Once a stage is satisfied, the blower associated with that 2. Check that burner venturi and ports are free of foreign matter.

stage will allow a 25 second postpurge before it deactivates.

3. Clean burners with bristle brush and/or vacuum cleaner.

DO NOT distort burner ports.

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.

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.

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.

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).

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.

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.

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.

•

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.

For installations above 4,500 feet (1350 m), refer to HIGHALTITUDE

INSTALLATIONS in the installation section.

THE FLOW OF COMBUSTION AIR TO THE BOILER MUST NOT BE

OBSTRUCTED.

THE BOILER AREA MUST BE KEPT CLEAR AND FREE FROM

COMBUSTIBLE MATERIALS, GASOLINEAND OTHER FLAMMABLE

VAPORSAND LIQUIDS.

Figure 17. Normal Flame Characteristics

Any safety devices including low water cutoffs used in conjunction

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.

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.

•

3. Remove burners from boiler and other metal parts as required

to clean as necessary.

More frequent inspections may be necessary depending on water

conditions.

•

Refer to parts list supplied with this manual for

disassembly aid.

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.

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.

HEATEXCHANGERPREVENTIVEMAINTENANCE

RELIEFVALVE

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.

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

CAUTION

THE WATER PASSING OUT OF THE VALVE DURING CHECKING

OPERATION MAY BE EXTREMELY HOT. BEFORE OPERATING

RELIEF VALVE, MAKE SURE DRAIN LINE IS INSTALLED TO DIRECT

DISCHARGE TO A SAFE LOCATION SUCH AS AN OPEN DRAIN,

TOAVOID SCALDING OR WATER DAMAGE.

LIME ACCUMULATION CAN REDUCE THE LIFE OF THE

EQUIPMENT, REDUCE EFFICIENCYAND WASTE FUEL. BOILER

FAILURE DUE TO LIME OR SCALE BUILDUP VOIDS THE

WARRANTY.

DELIMING

WARNING

SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAILTO

SHUT OFF, TURN OFF THE MANUAL GAS CONTROL VALVE TO

THE APPLIANCE.

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.

COMBUSTIONAIR 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.

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 COMPARTMENT

The time between cleaning will vary from two to six months

depending upon water conditions and usage. A change of

approximately 5^oF (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.

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.

TUBECLEANINGPROCEDURE

MECHANICAL REMOVAL OF DEPOSITS

VENTINGMAINTENANCE

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.

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

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.

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

FLAMMABLEAND MAY BE IGNITED BY STATIC ELECTRICITY. USE Inspect to ensure tubes are free of scale and deposits. If scaled,

AMETAL BRUSH TO MINIMIZE THE DANGER OF EXPLOSION.

remove deposits with a stiff wire brush or mechanical tube cleaner

to bare metal. Reinstall return header casting. Flush system.

Qualified serviceman should follow this procedure when the boiler's

intake and exhaust piping need cleaning:

Note: Removal of the heat exchanger is not required.

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.

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

EXPANDED INTO THE ROLLED TUBE TUB.

Hard Lockouts:

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 DETAILED INSTRUCTIONS.

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:

REPLACEMENT PARTS

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.

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.

A description of the red fault LEDs and their corresponding

functions are as follows.

LED

Controller Function

For Technical Assistance call A. O. Smith Technical Information

Center at 1-800-527-1953.

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.

TROUBLESHOOTING

Before any extensive troubleshooting, ensure that:

Insufficient Air

Indicates air pressure was too low to create

a sufficient differential to close the

differential pressure switch.

•

Power (120 VAC) is supplied to the appliance.

System control (tank probe, thermostat, etc.) is calling for

appliance operation (call for heat).

Circulate Fail

Gas Valve Fail

Indicates water flow was too low to close

the flow switch.

Monitors Gas Valve relay output. LED is ON

when the output relay supplying power to

the gas valve(s) is open.

Monitors ECO in the Outlet Temperature

probe. LED is ON when the ECO is open.

Monitors the Flame Sense Rod. LED is ON

when a signal from the flame rod is not

sufficient to indicate flame.

Indicates igniter current was too low to meet

minimum value which allows trial for

ignition to continue.

•

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.

High Limit

Flame Fail

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.

Igniter Fail

Low Gas Fail

High Gas Fail*

LWCO Fail*

Inlet gas pressure is not sufficient to close

gas pressure switch.

Manifold gas pressure is has exceeded

designed maximum value.

Indicates water level in system is too low for

safe operation.

CAUTION

MAKE SURE POWER IS DISCONNECTED FROM MAIN BREAKER

BEFORE SERVICING.

CAUTION

Power Vent Fail* Air pressure at Power Vent Switch is not

sufficient for safe operation.

LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN

SERVICING CONTROLS. WIRING ERRORS CAN CAUSE

IMPROPER FUNCTIONING OF UNIT RESULTING IN PROPERTY

DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.

*Optional Equipment - LEDs will illuminate only if equipment is

connected to boiler.

TROUBLESHOOTING IGNITION SYSTEM

Upon lockout, manually push the ENTER/RESET button on the

display panel to restart the boiler.

The control system has several features to aid in troubleshooting

problems which may occur during operation. If a fault occurs, the

Verify proper operation after servicing.

Table 19. Error Code Chart

FAULT

GENESIS II CONTROL - FAULT OPERATION

ERROR CODES

LOCKOUT

COMMUNICATIONS FAULT (CCB TO ICB)

STAGE 1:

STAGE 2:

STAGE 3:

STAGE 4:

001

002

003

004

HARD

ECO/HIGH LIMIT:

010

HARD

NO GAS VALVE POWER SENSED

STAGE 1:

STAGE 2:

STAGE 3:

STAGE 4:

LWCO

CIRCULATE FAULT (FLOW SWITCH)

011

012

013

014

020

030

HARD

SOFT

INSUFFICIENT AIR (AIR PRESSURE SWITCH)

STAGE 1:

STAGE 2:

STAGE 3:

STAGE 4:

BLOCKED FLUE

POWER VENT

041

042

043

044

060

070

SOFT

IGNITER FAILURE

STAGE 1:

STAGE 2:

STAGE 3:

STAGE 4:

081

082

083

084

090

HARD

LOW GAS FAILURE

HIGH GAS FAILURE

STAGE 1:

STAGE 2:

STAGE 3:

STAGE 4:

101

102

103

104

HARD

GAS VALVE RELAYFAILURE

STAGE 1:

STAGE 2:

STAGE 3:

STAGE 4:

111

112

113

114

HARD

FLAME FAILURE

STAGE 1:

STAGE 2:

STAGE 3:

STAGE 4:

121

122

123

124

HARD

PROBE FAULTS

OUTLET PROBE

INLET PROBE

REMOTE PROBE

IRI GAS VALVE FAILURE

CPU FAULT

131

132

133

140

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

NEW BOILER LIMITED WARRANTY

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. SERVICEAND 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 WARRANTIES

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

5621 West 115th Street

Alsip, IL 60803

A. O. Smith Enterprises Ltd.

P. O. Box, 310 - 768 Erie Street

Stratford, Ontario N5A 6T3

Telephone: (519) 271-5800

Telephone: 800 323-2636

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

INSTALLATION, OPERATION, REPAIR OR REPLACEMENTOFTHE BOILER. THE WARRANTOR SHALLNOTBE RESPONSIBLE FOR WATER DAMAGE,

LOSSOFUSEOFTHEUNIT, INCONVENIENCE, LOSSORDAMAGETOPERSONALPROPERTYOROTHERCONSEQUENTIALDAMAGE.THEWARRANTOR

SHALLNOT BE LIABLE BYVIRTUE OF THIS WARRANTYOR OTHERWISE FOR DAMAGE TOANYPERSONS OR PROPERTY, WHETHER DIRECT OR

INDIRECT,AND WHETHERARISING IN CONTRACTORTORT.

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. ____________________________________

FILLIN WARRANTYAND KEEPFOR FUTURE REFERENCE

REPLACEMENT PARTS

5621 W. 115TH STREET, ALSIP, IL 60803

Phone: 800-433-2545 Fax: 800-433-2515

www.hotwater.com E-Mail: [email protected]

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