AO Smith Water Heater 1000 User Guide

COPPER BOILERS FOR

HYDRONIC HEATING AND

HOT WATER SUPPLY

Instruction Manual

• Installation

GB/GW MODELS:

1000, 1300, 1500, 1850, 2100, 2500

• Operation

• Maintenance

• Limited Warranty

SERIES: 400, 401, 402, 403, 404, 405

CAUTION

TEXT PRINTED OR OUTLINED IN RED CONTAINS

INFORMATION RELATIVE TO YOUR SAFETY.

PLEASE READ THOROUGHLY BEFORE INSTALLING

AND USING THISAPPLIANCE.

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

efficient, high recovery unit from

Thank Y

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.

A. O. Smith Water Products Co.

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

DIMENSIONS/CAPACITIESDATA .......................... 2 - 3

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

FEATURES/CONTROLS ..................................... 5 - 7

INSTALLATION INSTRUCTIONS ....................... 7 - 9

VENTING ........................................................... 9 - 11

SYSTEM INSTALLATION ................................ 11 - 16

HYDRONIC INSTALLATION ............................ 16 - 18

HOT WATER SUPPLY INSTALLATION ........... 18 - 31

GAS CONNECTIONS ...................................... 18 - 23

OPERATION .................................................... 31 - 34

LIGHTING AND OPERATING .......................... 32 - 33

CONTROL SYSTEM ....................................... 34 - 44

PREVENTATIVE MAINTENANCE.................. 44 - 46

TROUBLE SHOOTING .................................... 42 - 44

WIRING DIAGRAM/SCHEMATIC ................... 24 - 27

LIMITED WARRANTY ............................................. 47

•

Extinguish any open flame.

Do not try to light any appliance.

Do not touch any electrical switch; do

not use any phone in your building.

Immediately call your gas supplier

from a neighbor's phone. Follow the

gas supplier's instructions.

•

If you cannot reach your gas supplier,

call the fire department.

Installation and service must be

performed by a qualified installer,

service agency or the gas supplier.

•

MC BEE, SC., RENTON, WA.,

STRATFORD-ONTARIO, VELDHOVEN-THE NETHERLANDS,

NANJING, CHINA

PLACE THESE INSTRUCTIONS ADJACENT TO BOILER AND

NOTIFYOWNERTOKEEPFORFUTUREREFERENCE.

www.hotwater.com / email:[email protected]

PRINTED IN U.S.A. 0906

212511-000

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DIMENSIONS/CAPACITIES DATA

IMPORTANT!

Refer to "Installation Clearances" section of manual

(page 7) for recommended service clearances prior

to boiler placement.

TOP VIEW

LEFT SIDE

FRONT VIEW

REAR VIEW

TABLE 1: GAS AND ELECTRICAL REQUIREMENT

Manifold Pressure

Electrical Characteristics

MODEL

Type of Gas Inches W.C. kPa

Volts/Hz

Amperes

GW/GB-1000

thru 2500

NATURAL

PROPANE

3.5

0.87

2.49

120/60

GW/GB-1000

thru 2500

120/60

All Models - Maximum Supply Pressure: 14.0 In. W.C. (3.49 kPa)

Minimum Supply Pressure Natural Gas: 6.0 In. W.C. (1.22 kPa)

Minimum Supply Pressure Propane Gas: 11.0 In. W.C. (2.74 kPa)

Minimum Pressures must be maintained during operating conditions.

Figure 1.

TABLE 2. DIMENSIONAL DATA

Model

Inches cm

Inches

cm Inches cm

GW/GB-1000 14.1

GW/GB-1300 24.8

GW/GB-1500 30.2

GW/GB-1850 27.7

GW/GB-2100 31.0

GW/GB-2500 38.1

35.8

63.0

76.7

70.4

78.7

96.8

12.2

11.2

10.5

31.0

28.4

26.7

40.3

43.0

102.4

109.2

31.6

32.3

80.3

82.0

26.0

39.3

44.6

44.0

49.5

56.5

66.0

99.8

113.3

111.8

125.7

143.5

46.8

57.3

64.3

78.3

85.3

99.3

118.9

145.5

163.3

198.9

216.7

252.2

Input Rating

KW BTU/Hr.

Natural Gas Natural Gas Propane Gas Propane Gas Inches

Exhaust

Vent Diameter

Air Intake

Diameter

BTU/Hr.

Water Conn. Gas Inlet

Size

Model

GW/GB-1000

25.4

30.5

35.6

40.7

Inches

20.3

25.4

30.5

990,000

289.95

380.74

439.31

541.82

615.04

729.26

990,000

1,300,000

1,500,000

1,850,000

2,100,000

2,490,000

289.95

380.74

439.31

541.82

615.04

729.26

2 1/2 NPT

2NPT

GW/GB-1300 1,300,000

GW/GB-1500 1,500,000

GW/GB-1850 1,850,000

GW/GB-2100 2,100,000

GW/GB-2500 2,490,000

2 1/2 NPT

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DIMENSIONS DATA FOR OUTDOOR CONFIGURATION

LEFT SIDE

REAR VIEW

FRONT VIEW

TOP VIEW

Figure 2.

TABLE 3. DIMENSIONAL DATA

Model

Inches cm Inches cm Inches cm Inches

cm Inches cm Inches cm Inches cm Inches cm Inches cm

GBO/GWO-1000

35.5

31.6

32.3

80.3

71.8

182.4

208.3

226

15.5

18.9

39.4

39.75

101

58.25

61.5

148

15.9

23.9

40.83

60.7

40.64 46.8 118.9

40.64 57.3 145.5

40.64 64.3 163.3

GBO/GWO-1300 24.75 62.9

GBO/GWO-1500

76.2

69.9

78.7

96.5

101

148

GBO/GWO-1850 27.5

103

110

124

261.6

279.4

315

109.2

156.2

50.8

78.3 198.9

85.3 216.7

99.3 252.2

GBO/GWO-2100

GBO/GWO-2500

61.5

60.7

61.5

60.7

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TABLE 4: RECOVERY CAPACITIES

TEMPERATURE RISE - DEGREES °F (°C)

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

Flow (22.2°) (27.7°) (33.3°) (38.8°) (44.4°) (50°) (55.5°) (61.1°) (66.7°) (72.2°)

Input Rating

BTU/Hr. (kW)

Water 40°F

50°F

MODEL

GW - 1000

990,000 (290.1)

GPH

LPH

2520 2016 1680 1440 1260 1120 1008 916

840

775

9526 7620 6350 5443 4763 4234 3810 3462 3175 2930

3309 2647 2206 1891 1655 1471 1324 1203 1103 1018

12508 10006 8339 7148 6256 5560 5005 4547 4169 3848

3818 3055 2545 2182 1909 1697 1527 1388 1273 1175

14432 11548 9620 8248 7216 6415 5772 5247 4812 4442

4709 3767 3139 2691 2355 2093 1884 1712 1570 1449

17800 14239 11865 10172 8902 7912 7122 6471 5935 5477

5345 4276 3564 3055 2673 2376 2138 1944 1782 1645

20204 16163 13472 11548 10104 8981 8082 7348 6736 6218

6338 5071 4225 3622 3169 2817 2535 2305 2113 1950

23958 19168 15971 13691 11979 10648 9582 8713 7987 7371

GW - 1300

GW - 1500

GW - 1850

GW - 2100

GW - 2500

1,300,000 (380.9) GPH

LPH

1,500,000 (439.5) GPH

LPH

1,850,000 (542.0) GPH

LPH

2,100,000 (615.3) GPH

LPH

2,490,000 (729.6) GPH

LPH

TABLE 5: PUMPING PERFORMANCE GUIDE

GB MODELS-FLOW, HEAD LOSS AND TEMPERATURE RISE

20 Deg. F Rise

30 Deg. F Rise

40 Deg. F Rise

Maximum Flow Rate

Minimum Flow Rate

GPM

PD-FT

Head

GPM

PD-FT

Head

GPM

PD-FT

Head

GPM PD-FT Deg. F

GPM

PD-FT

Head

Deg. F

Rise

MODEL

Head

12.2

14.5

16.3

18.5

21.3

23.2

Rise

GB - 1000

GB - 1300

GB - 1500

GB - 1850

GB - 2100

GB - 2500

109

126

154

n/a

5.1

7.2

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

72.8

10.1

18.5

n/a

6.3

103.6

117.6

139.4

10.1

14.5

18.5

77.7

n/a

104.6

105

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

(15.2 m) of normal pipe fittings.

MAKE SURE THE GAS ON WHICH THE BOILER WILL OPERATE

IS THE SAME AS THAT SPECIFIED ON THE BOILER RATING

PLATE.

FOREWORD

Detailed installation diagrams are in this manual. These diagrams

will provide the installer with a reference of materials needed and a

suggested method of piping. IT IS NECESSARY THAT ALL WATER

AND GAS PIPING,AND THE ELECTRICAL WIRING BE INSTALLED

AND CONNECTED AS SHOWN IN THE DIAGRAMS.

The boiler installation must conform to these instructions and the

local code authority having jurisdiction. In the absence of local

codes, the installation must comply with the latest editions of

the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and the

National Electrical Code, NFPA 70 or CAN/CSA B149.1, and CSA

2 C22.1. The former is available from the Canadian Standards

Association, 8501 East Pleasant Valley Road, Cleveland, OH

44131, and both documents are available from the National Fire

Protection Association, 1 Batterymarch Park, Quincy, MA 02269.

CHECK DIAGRAMS THOROUGHLY BEFORE STARTING

INSTALLATION TO AVOID POSSIBLE ERRORS AND MINIMIZE

TIMEAND MATERIALS COST. SEE FIGURES 1 THROUGH 5 AND

TABLES 1, 2, AND 3.

This design complies with the current edition of ANSI Z21.13-CSA

4.9 for Gas-Fired Low-Pressure Steam and Hot Water Boilers.

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GROUNDING INSTRUCTIONS

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

is odor fade, which is a loss of the chemical odorant that gives LP

gas its distinctive smell. Another cause can be your physical

condition, such as having a cold or diminishing sense of smell with

age. For these reasons, the use of a propane gas detector is

recommended. IF YOU EXPERIENCE AN OUT OF GAS

SITUATION, DO NOT TRYTO RELIGHTAPPLIANCES YOURSELF.

Call your local service agent. Only trained LP professionals should

conduct the required safety checks in accordance with industry

standards.

This boiler must be grounded in accordance with the National

Electrical Code, NFPA 70 or the Canadian Electrical Code CSA 2

C22.1 and/or local codes. The boiler is polarity sensitive, correct

wiring is imperative for proper operation.

This boiler must be connected to a grounded metal, permanent wiring

system, or an equipment grounding conductor must be run with the

circuit conductors and connected to the equipment grounding

terminal or lead on the boiler.

HIGHALTITUDE INSTALLATION

WARNING

YOUR BOILER IS NOT DESIGNED TO OPERATE WITHABOILER

INLET WATER TEMPERATURE OF LESS THAN 120°F (49°C).

COLDER INLET WATER TEMPERATURE WILL RESULT IN

SIGNIFICANT CONDENSATION DEVELOPING ON THE HEAT

EXCHANGER. THIS SITUATION CAN CAUSE A CORROSIVE

ENVIRONMENT FOR THE HEAT EXCHANGER, BURNERS AND

VENTING RESULTING IN PREMATURE DAMAGE, WHICH COULD

RESULT IN SERIOUS PERSONAL INJURY OR DEATH.

WARNING

INSTALLATIONS ABOVE 4,500 FEET REQUIRE REPLACEMENT

OF THE BURNER ORIFICES. FAILURE TO REPLACE THE

ORIFICES WILL RESULT IN IMPROPER AND INEFFICIENT

OPERATION OF THE APPLIANCE, PRODUCING CARBON

MONOXIDE GAS IN EXCESS OF SAFE LIMITS, WHICH COULD

RESULT IN SERIOUS PERSONAL INJURY OR DEATH.

GENESIS BOILERS ARE EQUIPPED WITH SELF-REGULATING

PREJET ORIFICES WHICHAUTOMATICALLY COMPENSATE FOR

HIGHER ELEVATIONS AND ADJUST THE APPLIANCE'S INPUT

RATEACCORDINGLY, MAKING IT UNNECESSARY TO REPLACE

ORIFICES FOR HIGHALTITUDE (UP TO 4,500 FEET). CONSULT

THE FACTORY FOR HIGHERALTITUDES.

FOR SYSTEMS THAT USE LARGE VOLUMES OF COLD WATER

OR SYSTEMS UTILIZING HEAVY WATER DRAWS, CONDENSATION

CAN BE PREVENTED BY USINGABYPASS LOOP.

CORRECT GAS

Some utility companies derate their gas for altitude. You should

contact your gas supplier for any specific changes which may be

required in your area. Call the local gas utility to verify BTU content

of the gas supplied.

Make sure the gas on which the boiler will operate is the same as

that specified on the boiler rating plate. Do not install the boiler if

equipped for a different type of gas, consult your gas supplier.

PRECAUTIONS

Input rating specified on the rating plate applies to elevations up to

4,500 feet (1350 m). For elevations above 4,500 feet (1350 m),

ratings must be reduced, consult the factory.

IF THE UNIT IS EXPOSED TO THE FOLLOWING, DO NOT

OPERATE UNTILALLCORRECTIVE STEPS HAVE BEEN MADE BY

A QUALIFIED SERVICEMAN:

FEATURES/CONTROLS

1. EXPOSURE TO FIRE.

2. IF DAMAGED.

MULTI-STAGE FIRING AND CONTROLSYSTEM

3. FIRING WITHOUT WATER.

4. SOOTING.

ALL MODELS - The control system consists of four basic

components: 1) Central Control Board 2) Flame Control Board 3)

User Interface Module 4) Power Distribution Board; see Figures

17, 18, 19 and 21. The Central Control Board, Flame Control

Boards and the Power Distribution Board are located in the

control box and can be accessed through panels on the left side

and top of the unit. The User Interface Module is attached to the

front jacket panel. The control system is a multi-stage control

capable of managing three or four firing stages. Models 1000,

1300, and 1500 operates with 3-stage fire. Models 1850, 2100

and 2500 operates with 4-stage fire. Every system will have one

Central Control Board (CCB), one Power Distribution Board

(PDB), one User Interface Module (UIM) and either two or three

Flame Control Boards (FCB) depending on the model.

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

REPLACED.

LIQUID PETROLEUM MODELS

Boilers for propane or liquefied petroleum gas (LPG) are different

from natural gas models. A natural gas boiler will not function

safely on LP gas and no attempt should be made to convert a

boiler from natural gas to LP gas.

LP gas must be used with great caution. It is highly explosive and

heavier than air. It collects first in the low areas making its odor

difficult to detect at nose level. If LP gas is present or even suspected,

do not attempt to find the cause yourself. Leave the building, leaving

The Control Boards Figure 17 and 18, contain dipswitches which

doors open to ventilate, then call your gas supplier or service agent. allow the user to control several system options. See Control System

Section.

Keep area clear until a service call has been made.

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DIFFERENTIAL PRESSURE SWITCH

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 might require slight adjustment depending

on site installation.

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, combustion and proper low NO emission. The

switch has two pressure taps marked "+" (positive) and "-" (negative).

Silicone tubing is run from the positive pressure tap of the switch to a

tap on the control panel to measure the air pressure in 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.

TANK PROBE

FOR HOT WATER SUPPLY SYSTEMS (GW models), a tank probe

is supplied with each hot water supply boiler.

Note: The tank probe must be designated as the controlling probe

using dip switch "4" on Central Control Board (Figure 17) before it

can be used for (GW) hot water supply applications.

The differential pressure switch is normally open and closes when

the combustion blower starts.

"Pigtails" of field-supplied wires should be spliced to "pigtails" of

tank probe and connected to terminal block in the 24VAC junction

box. See Figure 12 for the tank probe installation. Follow the

instructions in the "TANK PROBE INSTALLATION PROCEDURE".

See page 18.

BLOCKED FLUE PRESSURE SWITCH

The blocked flue pressure switch ensures that the vent system is

clear. This pressure switch is normally closed and only opens on

fault conditions.

FOR HOT WATER HEATING SYSTEMS (GB models), a tank probe

is not supplied with the GB models due to the many various

types of systems and operating conditions. A tank probe can

be used as an option to control loop temperature and unit

staging. Additionally, the inlet temperature probe can be used

as the loop thermostat in some heating applications. The tank

probe connects to designated wires in the junction box at the

rear of the boiler. Do not operate this boiler using the internal

high limits only, use a tank probe or operating thermostat to

control system temperatures.

FLAME SENSOR

The flame sensor detects the flame presence on burner's ports. If

no flame is sensed, the gas valve(s) will close automatically. If no

flame is sensed on three ignition trials the boiler will lock out. In the

event of a lockout, depress the SELECT button on the UIM to restart

the boiler.

WATER FLOW SWITCH

The water flow switch is installed at the boiler outlet to prevent burner

operation in the event of inadequate water flow through the boiler. It

is a normally open switch that will close its contacts when increasing

water flow rate is detected. The water flow switch is factory-set, but

may require field adjustment. The contacts will open when the flow

rate drops below the adjusted setting causing the gas valve(s) to

close which will turn off the gas to the burners.

Note: The tank probe or additional 24VAC devices must be identified

using Dipswitches on Central Control Board before they are

recognized as a part of the heating system; see Table 5. Refer to

"Control System" section for more information about dipswitch

settings.

CIRCULATING PUMP

LIMIT CONTROLS

The pump flow rate should not exceed the maximum

recommended flow rate; see Table 5.

CAUTION

LIMIT CONTROLS ARE SAFETY DEVICES AND ARE NOT TO BE

USED AS AN OPERATING CONTROL (THERMOSTAT).

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.

The "G(B/W)" models incorporate an outlet water probe consisting

of two limit controls:

1. An adjustable automatic reset limit control, that can be set

as high as either 210°F (99°C) or 235°F (113°C) depending on

the application.

FOR HOT WATER HEATING SYSTEMS (GB models or GW models

ordered without circulator), the circulator is NOT provided and

must be field-installed.

2. A fixed manual reset limit (ECO) factory set at 244°F

(118°C). If the manual reset should open due to high

temperature, the gas valves will close and the unit will go into

lockout. If lockout occurs, push the SELECTION button on the

UIM to restart the boiler.

LOW WATER CUTOFF (Not Supplied)

If low water level protection is required by the authorities having

jurisdiction, a low water cutoff switch should be installed

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

"HYDRONIC INSTALLATION" section; see page 16. The switch

should receive periodic (every six months) inspection to assure

proper operation. A low water cutoff device of the float type should

ON/OFF SWITCH

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

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

be flushed every six months.

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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.

DRAIN VALVE (Not Supplied)

Additional drain valves must be obtained and installed on each boiler

and tank for draining purposes.

SAFETY RELIEF VALVES

Your local code authority may have other specific relief valve

requirements not covered below.

INSTALLATION INSTRUCTIONS

REQUIRED ABILITY

WARNING

THE PURPOSE OF A SAFETY RELIEF VALVE IS TO AVOID

EXCESSIVE PRESSURE WHICH MAY CAUSE TANK EXPLOSION,

SYSTEM OR BOILER DAMAGE.

INSTALLATION OR SERVICE OF THIS BOILER REQUIRESABILITY

EQUIVALENTTOTHATOFALICENSED TRADESMAN IN THE FIELD

INVOLVED. PLUMBING,AIR SUPPLY, VENTING, GAS SUPPLYAND

ELECTRICAL WORK ARE REQUIRED.

TOAVOID WATER DAMAGEADRAIN LINE MUST BE CONNECTED

TOASAFETY RELIEF VALVE FOR DIRECT DISCHARGE TOASAFE

LOCATION. ADRAIN LINE MUST NOT BE REDUCED FROM THE

SIZE OF THE VALVE OUTLETAND IT MUST NOT CONTAIN ANY

VALVES BETWEEN THE BOILER AND THE RELIEF VALVE OR

THE RELIEF VALVEAND THE DRAIN EXIT. INADDITION, THERE

SHOULD NOT BE ANY RESTRICTIONS IN A DRAIN LINE NOR

SHOULD IT BE ROUTED THROUGHAREAS 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. The location selected should be as close to the stack or

chimney as practical with adequate air supply and as centralized

with the piping system as possible. The location should also be

such that the gas ignition system components are protected from

water (dripping, spraying, etc.) during appliance operation and

service (circulator replacement, control replacement, etc.)

•

THE BOILER MUST NOT BE INSTALLED ON CARPETING.

THE BOILER SHOULD NOT BE LOCATED INANAREAWHERE

IT WILL BE SUBJECT TO FREEZING.

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 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.

The storage tank temperature and pressure relief valve must

comply with the applicable construction provisions of the Standard

for Relief Valves for Hot Water Supply Systems, ANSI Z21.22-CSA-

4.4 (current edition). The valve must be of the automatic reset type

and not embody a single-use type fusible plug, cartridge or linkage.

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.

FOR HOT WATER HEATING SYSTEMS, the boilers are shipped

with a 50 psi pressure relief valve. This relief valve is factory

installed on the water outlet header of the boiler.

WARNING

FOR HOT WATER SUPPLY SYSTEMS, the boilers are shipped

with a 125 psi pressure relief valve. This relief valve is factory

installed on the water outlet header of the boiler. This ASME-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.

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 SUCHANAREACANNOT BEAVOIDED.

In addition, a CSA design-certified and ASME-rated temperature

and pressure (T & P) relief valve must be installed on every water

storage tank in the hot water supply system; see

Figures 11 and 13.

FLAMMABLE ITEMS, PRESSURIZED CONTAINERS OR ANY

OTHER POTENTIALFIRE HAZARDOUSARTICLES MUST NEVER

BE PLACED ON OR ADJACENT TO THE BOILER.

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 OPEN CONTAINERS OF FLAMMABLE MATERIAL SHOULD NOT

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

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

storage tank.

Locate the T & P relief valve (a) in the top of the tank, or (b) in the

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the authority having jurisdiction, must be provided with a low water

cutoff device either as a part of the boiler or at the time of boiler

installation.

WARNING

UNDER NO CIRCUMSTANCES SHOULD THE EQUIPMENT ROOM

WHERE THE BOILER IS INSTALLED EVER BE UNDER NEGATIVE

PRESSURE. PARTICULAR CARE MUST BE TAKEN WHEN

EXHAUST FANS, COMPRESSORS,AIR HANDLING EQUIPMENT,

ETC., MAY INTERFERE WITH THE COMBUSTION AND

VENTILATIONAIR SUPPLIES OF THIS BOILER.

MODEL

COMBUSTIBLE BASE KIT NUMBER

CHEMICAL VAPOR CORROSION

G(B,W) - 1000

G(B,W) - 1300

G(B,W) - 1500

G(B,W) - 1850

G(B,W) - 2100

G(B,W) - 2500

211093

211093-1

211093-2

211093-3

211093-4

211093-5

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.

Figure 3. Boiler on Combustible Floor Base and Kit Numbers.

LEVELLING

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.

Each unit must be checked after installation to be certain that it is level.

AIR REQUIREMENTS

WARNING

INSTALLATION CLEARANCES

FOR SAFE OPERATION, AN AMPLE SUPPLY OF AIR MUST BE

PROVIDED FOR PROPER COMBUSTION AND VENTILATION IN

ACCORDANCE WITH THE NATIONAL FUEL GAS CODE, ANSI

Z223.1 OR CAN/CSA-B149.1 CURRENT EDITION ORAPPLICABLE

PROVISIONS OF THE LOCAL BUILDING CODES. AN

INSUFFICIENT SUPPLY OF AIR MAY RESULT IN A YELLOW,

LUMINOUS BURNER FLAME, CARBONING OR SOOTING OF THE

FINNED HEAT EXCHANGER, OR CREATE A RISK OF

ASPHYXIATION. DO NOT OBSTRUCT THE FLOW OF

COMBUSTIONAND VENTILATIONAIR.

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.

UNCONFINED SPACE

In buildings of conventional frame, brick or stone construction,

unconfined spaces may provide adequate air for combustion.

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.

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.

Access to control box items such as the Central Control Board,

Flame Control Boards, Power Distribution Board and wiring

harnesses is provided through a panel on the left side of the unit.

A minimum service clearance of 18" (46.0 cm) is required.

CONFINED SPACE

These boilers are approved for installation on noncombustible

flooring in an alcove with minimum clearance to combustibles of:

3 inches (7.6 cm) Right Side, and Back; 6 inches (15.2 cm) Top;

Front, Alcove; 12 inches (30.5 cm) Left Side; and 6 inches

(15.2 cm) surrounding the Vent.

(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 TOPAND ONE WITHIN

For installation on combustible flooring use the Combustible Floor

Kit. The combustible floor kit base adds 4" (10.1 cm) to the overall 12 INCHES OF THE ENCLOSURE BOTTOM. Each opening shall

have a free area of at least one square inch per 1000 Btu/hr

height of the boiler. See Figure 3.

(22 cm²/k W) of the total input of all appliances in the enclosure.

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If the confined space is within a building of tight construction, air

for combustion, ventilation, and draft hood dilution must be

obtained from outdoors. When directly communicating with the

outdoors or communicating with the outdoors through vertical

ducts, two permanent openings, located in the above manner,

shall be provided. Each opening shall have a free area of not less

than one square inch per 4000 Btuh (5.5 cm²/kW) of the total input

of all appliances in the enclosure. If horizontal ducts are used, each

opening shall have a free area of not less than one square inch per

2000 Btuh (11 cm²/kW) of the total input of all appliances in the

enclosure.

SEE FIGURE 6). AT LEAST TYPE B VENTING MUST BE USED

WITH THE STANDARD VENTING OPTION (thru-the-roof) USING

THE NATIONAL FUEL GAS CODE VENT TABLES. TYPE B VENT

PIPE CANNOT BE USED IF THE BOILER IS VENTED

HORIZONTALLY OR AS A DIRECT VENT (SEE PAGES 12

THROUGH 15). ALL LOCAL UTILITY, STATE/ PROVINCIAL,

REGULATIONS ON VENTING MUST BE FOLLOWED.

VENT SIZING, VENT CONNECTORS, INSTALLATION AND

TERMINATION SHALLBE INACCORDANCE WITH THE CURRENT

EDITION OF NATIONAL FUEL GAS CODE, ANSI Z223.1 OR CAN/

CSA-B149.1 or applicable provisions of the local building codes.

Size and install proper size vent pipe; refer to Table 6.

(b) CANADIAN INSTALLATIONS

Ventilation of the space occupied by the boiler(s) shall be provided

by an opening for ventilation air at the highest practical point

communicating with outdoors. The total cross-sectional area shall

be at least 10% of the area of the combustion air opening but in no

case shall the cross-sectional area be less than 10 square inches

(64.5 cm²).

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.

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 (3.2 cm²/kW) up to and including 1,000,000

BTUH plus 1 square inch per 14,000 BTU (1.6 cm²/kW) in excess of

1,000,000 BTUH. This opening(s) shall be located at, or ducted to,

a point neither more than 18" (46.0 cm) nor less than 6 inches (15.2

cm) above the floor level.

TABLE 6: VENT CONNECTION

MODEL NUMBER

G(B,W) 1000

G(B,W) 1300

G(B,W) 1500

G(B,W) 1850

G(B,W) 2100

G(B,W) 2500

VENT CONNECTOR

10" (25.4 cm)

12" (30.5 cm)

14" (35.6 cm)

16" (40.6 cm)

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

boiler, sufficient air openings must be supplied. UNDERSIZED

OPENINGS MAY RESULT IN INSUFFICIENT AIR FOR

COMBUSTION.

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

sufficient openings for air must be provided in the walls.

UNDERSIZED OPENINGS WILL CAUSEAIR TO BE DRAWN INTO

THE ROOM THROUGH THE CHIMNEY, CAUSING POOR

COMBUSTION. SOOTING MAY RESULT WITH AN INCREASED

RISK OFASPHYXIATION.

For vent arrangements other than Table 10 and for proper boiler

operation, a barometric damper is required to maintain draft

between -0.02" W.C.. and -0.04" W.C. at 2 feet (0.6 m) above the

boiler vent collar.

VENTING

STANDARD (HORIZONTAL) VENTING, CATEGORYIII

CAUTION

Vent sizing, installation and termination shall be in accordance

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

CAN/CSA-B149.1 (Current Editions). If applicable, all local, utility,

state/provincial regulations on venting must be followed. See Table

11, Figure 7 for venting specifications. The exhaust vent pipe must

be of a type listed for use with Category III gas burning heaters such

as "Saf-T-Vent" manufactured by Heat-Fab Inc.

WHEN VENTING THE GENESIS BOILER THROUGH AN

OVERSIZED CHIMNEY (INCLUDING MASONRY CHIMNEYS),

ADDITIONAL CARE MUST BE EXERCISED TOASSURE PROPER

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

W.C.ANDAMAXIMUMDRAFTOF-0.04"W.C. MUSTBEMAINTAINED.

IN INSTANCES OF EXCESSIVE DRAFT, ABAROMETRIC DAMPER

MAY BE REQUIRED TO ASSIST IN MAINTAINING THE PROPER

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

THE BOILER VENT COLLAR.

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

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

installation. For Horizontal Vent Kit part numbers, see Table 7.

WARNING

TABLE 7: HORIZONTALVENT KITS.

HORIZONTAL VENT KIT

211426

MODEL

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.

G(B,W) 1000

G(B,W) 1300

G(B,W) 1500

G(B,W) 1850

G(B,W) 2100

G(B,W) 2500

211426-1

211426-2

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.

211426-3

DIRECT VENT VERTICALAND HORIZONTAL VENTING

STANDARD (VERTICAL) VENTING, CATEGORY I

For direct vent applications, this boiler may be vented according to

Tables 12 and 13; see Figures 8 and 9. For category III applications,

THIS BOILER MAY BE VENTEDACCORDING TO TABLE 10 (ALSO

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POWER VENT (OPTIONAL)

the exhaust vent pipe must be listed for use with category III gas

burning heaters such as "Saf-T-Vent" manufactured by Heat-Fab

Inc. This vent system must be 100% sealed with a condensate

trap located as close to the boiler as possible. When sizing exhaust

piping and intake air piping, 90-degree elbows are equivalent to 10

feet (3.1 m) of straight pipe and 45-degree elbows are equal to 5

feet (1.5 m) of straight pipe.

The length of vent used in horizontally vented installations can be

extended beyond the lengths shown in Tables 11 and 13 by

implementing the kits listed below:

TABLE 9: POWER VENT KITS.

POWER VENT KIT NO.

MODEL

MAX. LENGTH

The intake air piping can be PVC, CPVC, ABS, Galvanized steel or

any suitable intake air piping that can be sealed. See Table 8 for

Direct Vent Kit numbers.

211499

G(B,W) 1000

G(B,W) 1300

G(B,W) 1500

G(B,W) 1850

G(B,W) 2100

G(B,W) 2500

110' (33.5 m)

100' (30.5 m)

211499-1

211499-2

211499-3

211499-4

TABLE 8: DIRECT VENT KITS.

HORIZONTAL DIRECT VENT KIT NO.

MODEL

211090

G(B,W) 1000

G(B,W) 1300

G(B,W) 1500

G(B,W) 1850

G(B,W) 2100

G(B,W) 2500

211090-1

211090-4

211090-2

211090-3

CONNECTING BOILER TO A COMMON VENT

Do not connect the boiler to a common vent or chimney with solid

fuel burning equipment. This practice is prohibited by most local

building codes as is the practice of venting gas fired equipment to

the duct work of ventilation systems.

VERTICAL DIRECT VENT KIT NO.

MODEL

G(B,W) 1000

G(B,W) 1300

G(B,W) 1500

G(B,W) 1850

G(B,W) 2100

G(B,W) 2500

MODEL

211089

211089-1

211089-4

211089-2

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.

211089-3

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.

AIR INTAKE TERMINAL

191965-2

G(B/W) 1000

211336

G(B/W) 1300,1500,1850

211336-1

G(B/W) 2100, 2500

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.

HORIZONTALVENT INSTALLATION

This boiler can be vented through the rear of the cabinet with the

use of the fluebox and vent adaptor. Any of the previous venting

configurations can be installed with rear connections.

1. Seal any unused opening in the common venting system.

To change the unit to rear exhaust:

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.

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

and rear of the unit.

3. Insofar as is practical, close all building doors, windows and

all doors between the space in which the appliances remaining

connected to the common venting system are located and other

spaces of the building. Turn on clothes dryers and any

appliance not connected to the common venting system. Turn

on any exhaust fans, such as range hoods and bathroom

exhausts, so they will operate at maximum speed. Do not

operate a summer exhaust fan. Close fireplace dampers.

2. Trim the insulation from around the rear flue hole in the jacket

and the fluebox. Support insulation from inside the fluebox to

facilitate cutting. Use safety precautions such as gloves. Place

the gasket and vent adaptor in the horizontal position. Place

the gasket and flue plate in the vertical position as shown in

Figure 4.

4. Test fire the appliance(s) being inspected, making sure to follow

the manufacturers lighting and operating instructions.

Appliance(s) operating controls should be adjusted to provide

continuous service.

5. Check vent pressure of the appliance 24 inches (61.0 cm) above

boiler vent collar. Vent pressure should be maintained between

-0.02" W. C. and -0.04" W.C. to assure proper operation. For

appliances with a draft hood, check for spillage with mirror,

smoke or other device five minutes after placing appliance in

operation.

6. After it has been determined that each appliance remaining

connected to the common venting system properly vents when

tested as outlined above, return doors, windows, exhaust fans,

Figure 4. Switching from Vertical to Horizontal Venting.

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fireplace dampers and other gas burning appliances to their

previous conditions of use.

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.

All boiler venting systems shall be installed in accordance with

the National Fuel Gas Code, ANSI Z223.1 or CAN/CSA-B149.1

(current edition), or applicable provisions of the local building

codes.

8. Select the point of wall penetration where the minimum

1/4" per foot (2 cm/m) of slope up can be maintained.

INTAKE/EXHAUST INSTALLATION REQUIREMENTS

9. The through the wall termination kit is suitable for zero

clearance to combustible materials.

1. The termination must be 12 inches (30.5 cm) above snow

or grade level whichever is higher.

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

of 12 inches (30.5 cm) from the exterior wall.

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.

SYSTEM INSTALLATION

GENERAL

If the system is to be filled with water for testing or other purposes

during cold weather and before actual operation, care must be taken

to prevent a down draft entering the boiler or freezing air from contacting

the system. Failure to do so may cause the water in the system to

freeze with resulting damage to the system. Damage due to freezing

is not covered by the warranty.

3. The exhaust terminal of the venting system must maintain

a minimum clearance of 4 feet (1.22 m) horizontally from,

and in no case above or below, unless a 4-foot horizontal

distance is maintained, from electric meters, gas meters,

regulators and relief equipment.

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

The boilers described in this manual may be used for space (hydronic)

heating or for the heating of potable water. If the heater is to be used for

hydronic space heating, follow the instructions on pages 16-17 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 18-20; see Figures 11 and 13.

Installations must comply with all local codes.

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. Fresh air or make up air inlet such

as a dryer or furnace area is considered to be a forced

air inlet.

INSTALLATIONAS BOILER REPLACEMENT

Installation as boiler replacement on an old system with large water

STANDARD VENTING

DIRECT VENT APPLICATIONS

CAUTION

DIRECT VENTING INTO DEAD AIR SPACES

SUCH AS ALLEYS, ATRIUMS AND INSIDE

CORNERS CAN CAUSE RECIRCULATION OF

FLUE GASES. RECIRCULATION OF FLUE

GASES WILLCAUSE 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 BETWEENTHE COMBUSTIONAIR

INTAKEANDTHE EXHAUSTVENTTERMINAL.

Note: Venting system of other than

direct-vent appliance shall terminate at

least 4 ft. (1.2 m) below, 4 ft. (1.2 m)

horizontally from, or 1 ft. (30.0 cm)

above any door window or gravity air

inlet.

Figure 5. Vent Termination Installation Clearances

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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 6.

TABLE 10. STANDARD VERTICAL VENTING (CATEGORY I)

APPLIANCE

CATEGORY

CERTIFIED

VENTING

MATERIAL

EXHAUST

VENT SIZE

INCHES (cm)

MAXIMUM

VENT LENGTH

FEET (m)

MODEL

I000

STAINLESS

STEEL

III

70' (21.3 m)

35' (10.7 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 fromA.O. Smith, 500 Tennessee Waltz Parkway, Ashland City, TN 37015 Phone: 1-800-433-2545

or Fax: 1-800-433-2515. Pipe joints must be positively sealed.

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DIRECT VENT - VERTICAL (CATEGORY I)

Figure 8.

TABLE 12. DIRECT VENT (VERTICAL EXHAUST CONFIGURATIONS)

APPLIANCE CERTIFIED EXHAUST VENT MAXIMUM

AIR INTAKE

EXHAUST VENT MATERIAL

INCHES (cm) LENGTH FT (m)

AIR INTAKE

SIZE

INCHES (cm) LENGTH FT (m)

MAXIMUM

AIR INTAKE

MODEL CATEGORY EXHAUST VENT

MATERIAL

SIZE

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

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.

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DIRECT VENT - HORIZONTAL (CATEGORY III)

Figure 9.

TABLE 13. DIRECT VENT (HORIZONTAL EXHAUST CONFIGURATIONS)

APPLIANCE

CERTIFIED

EXHAUST

MAXIMUM

AIR INTAKE

SIZE

MAXIMUM

AIR INTAKE

MODEL CATEGORY EXHAUST VENT VENT SIZE EXHAUST VENT MATERIAL

MATERIAL

INCHES (cm) LENGTH FT (m)

INCHES (m) LENGTH FT (m)

GAL. STEEL

PVC, ABS OR

CPVC

10"

35'

STAINLESS

(SEALED)

III

I000

(25.4 cm)

(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, 500 Tennessee Waltz Parkway, Ashland City, TN 37015 Phone: 1-800-433-2545 or

Fax: 1-800-433-2515. Pipe joints must be positively sealed.

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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.

HYDRONIC INSTALLATION

The following is a brief description of the equipment required for

installations noted in Figure 10. All installations must comply with

local codes.

BYPASS BALANCING

TABLE 14: INSTALLATION ITEMS

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.

NO. SUGGESTED ITEMS FOR INSTALLATION

1. PAIR OF SHORT PIPE NIPPLES, PAIR OF BOILER

LOOPTEESAND BALL VALVE BETWEEN SYSTEM

SUPPLY AND RETURN - ONE SET PER EACH BOILER

2. BOILER PIPE LOOP (See Table 5.)

3. BOILER CIRCULATING PUMP (See Table 5.)

4. THERMOMETER

AIR SEPARATOR

5. PRESSURE GAUGE

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

7. FLOW SWITCH (Factory-Installed)

An air separator as shown in the piping diagram is recommended

especially for modern commercial hydronic systems.

8. PRESSURE RELIEF VALVE (Factory-Installed)

9. BOILER INLET - OUTLET

10. SYSTEM SUPPLYTEMPERATURE THERMOMETER

VENT VALVES

It is recommended that automatic, loose key or screwdriver type

vent valves be installed at each convector or radiator.

11. DRAIN or BLOW-DOWN VALVE

WATER SUPPLY LINE

SYSTEM HEADERS

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. See Figure 10. Severe damage will

occur if the boiler is operated without proper water flow

circulation.

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 abalancing cock in each return line.

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. 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. AMINIMUM 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.

Manifold headers are recommended for split systems with or

without zone valves and also those installations with zone

circulators. If the system is to be split at remote points, good practice

requires special attention be given to main pipe sizing to allow

balancing of water flow.

COOLING PIPING

When the boiler is used in conjunction with a refrigeration system

it must be installed so that the chilled medium is piped in parallel

with the boiler. Appropriate valves, manual or motorized, must be

provided to prevent the chilled medium from entering the boiler.

CONVENTIONAL SPACE HEATING INSTALLATION

Water temperature in the heating system must be reduced to less

than 100°F (38°C) before cooling system is started, or damage to

the chiller unit may occur.

Modern copper-finned tube 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.

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.

Refer to Table 5 showing flow rate vs. pressure drop and

temperature rise.

Figure 10 shows a typical installation of the boiler.

A system with several flow controlled zones, or with a 3-way mixing

valve system could present a flow rate to the boiler of less than

required for a maximum of 50°F (28°C) temperature rise. Design

system with compensating bypasses to the boiler.

EXPANSION TANK

Install an expansion tank as shown in Figures 10, 11, and 13. The

sizing of the expansion tank is very important and is directly related

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

reliable specifications for sizing.

A system bypass should be installed as shown in Figure 10 to

prevent boiler circulation starvation when the system zones call for

reduced flow.

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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.

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.

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.

24 VAC System Controller (Optional)

GB models require a field supplied 24VAC operating control to be

installed in the system such as: loop thermostat, indoor/outdoor reset

control, sequencing panel, or energy management system. The

connection for such devices is located in the 24 VAC junction box at

the rear of the unit. A24 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.

SPACE HEATING APPLICATIONS

Controlling of these systems is decided mainly by the type of

building system controlling that is desired. Asingle boiler 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.

INTERNAL CONTAMINANTS

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.

Individual controls, or the separate stages of a step controller, should

start the boiler loop circulator and fire the boiler. Some large

installations may require the firing of more than one boiler per stage.

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.

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.

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.

Multiple boiler installations are especially adapted to the use of

outdoor reset for main water temperatures. This feature is not

mandatory but offers smooth, efficient operation of a modern

system.

It is recommended that after installation, the boiler and system

when filled should include the proper percentage of cleaning solution

Normal use of flow control valves is required to prevent cross

circulation of zones as with any multiple pump system.

Figure 10. Single or Multiple Boiler Installation Diagram

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related to approximate water volume of the system. The system

should be turned on to circulate water mix for about one hour and

then flush clean with fresh water.

limit the maximum tank probe temperature for GW applications.

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.

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.

Refer to "Connection Diagram" in order to connect the tank probe

to the boiler. See Figures 12 and 15.

THE WATER HEATER SHOULD BE LOCATED INANAREAWHERE

THE GENERAL PUBLIC DOES NOT HAVE ACCESS TO BOILER See section titled "Temperature Setpoints" for instructions on how

to set the temperature.

CONTROLS.

HOT WATER SUPPLY

BOILER INSTALLATION

GAS CONNECTIONS

WARNING

WATER LINE CONNECTIONS

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

MALFUNCTIONOFTHESUPPLYSYSTEM,THEGASVALVESMUSTBE

CHECKEDFORSAFEOPERATION. MAKESURETHATTHEOUTSIDE

VENTSONTHESUPPLYREGULATORSANDTHESAFETYVENTVALVES

ARE PROTECTED AGAINST BLOCKAGE. THESE ARE PARTS OF

THE GAS SUPPLY SYSTEM, NOTTHE BOILER. VENT BLOCKAGE

MAY OCCUR DURING ICE BUILD-UP OR SNOW STORMS.

Where excessive heat exchanger condensation exists due to

continued low inlet water temperatures below 120°F (49°C), a

bypass balance loop must be installed. See Figures 10 and 12.

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.

WHEN LOCAL CODES REQUIRE A MAIN MANUAL SHUT-OFF

VALVE OUTSIDE THE BOILER JACKET, A SUITABLE MAIN

WARNING

LIME ACCUMULATION CAN REDUCE THE LIFE OF THE MANUAL SHUT-OFF VALVE MUST BE INSTALLED INALOCATION

EQUIPMENT, REDUCE EFFICIENCYAND WASTE FUEL. BOILER

FAILURE DUE TO LIME OR SCALE BUILDUP VOIDS THE

WARRANTY.

COMPLYING WITH THOSE CODES.

IT IS IMPORTANT TO GUARD AGAINST GAS VALVE FOULING

FROM CONTAMINANTS IN THE GAS WAYS. SUCH FOULING

MAY CAUSE IMPROPER OPERATION, FIRE OR EXPLOSION. IF

COPPER SUPPLY LINES ARE USED THEY MUST BE

Tank Probe (Optional)

In addition to the Inlet and Outlet/ECO Probes, units can be APPROVED FOR GAS SERVICE.

optionally equipped with a tank probe. The connection for the tank

BEFORE ATTACHING THE GAS LINE BE SURE THAT ALL GAS

PIPE IS CLEAN ON THE INSIDE.

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 Procedure" section below for

additional information.

TO TRAP ANY DIRT OR FOREIGN MATERIAL IN THE GAS

SUPPLY LINE, A DIRT LEG (SOMETIMES CALLED DRIP LEG)

MUST BE INCORPORATED IN THE PIPING. THE DIRT LEG

MUST BE READILY ACCESSIBLE AND NOT SUBJECT TO

FREEZING CONDITIONS. INSTALL IN ACCORDANCE WITH

RECOMMENDATIONS OF SERVING GAS SUPPLIERS. REFER TO

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

(current edition).

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

24VAC 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.

THE BOILER AND ITS INDIVIDUAL SHUTOFF VALVE MUST BE

DISCONNECTED FROM THE GAS SUPPLY PIPING SYSTEM

DURING ANY PRESSURE TESTING OF THAT SYSTEM AT TEST

PRESSURES IN EXCESS OF 1/2 PSI (3.5 KPA).

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 “SW1-4” must be set to the “ON”

position to designate the tank probe as the controlling probe.

Second, Dip Switch “SW1-1” must be set to the “OFF” position to

THE BOILER MUST BE ISOLATED FROM THE GAS SUPPLY

PIPING SYSTEM BY CLOSING ITS INDIVIDUAL MANUAL

SHUTOFF VALVE DURING ANY PRESSURE TESTING OF THE

GAS SUPPLY PIPING SYSTEMATTEST PRESSURES EQUALTO

OR LESS THAN 1/2 PSI (3.5KPA).

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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

WATER 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 26. 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. SPECIAL CARE MUST BE TAKEN TO

ENSURE PROPER SUPPORT.

TWO TEMPERATURE WATER

MIXING VALVE APPLICATION

MINIMUM

MODELS PIPE SIZE

MODELS

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, CONNECTTOANY OPENING

NEAR BOTTOM OF TANK.

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 15. This conduit and

wiring should be separate from

any other conduit/wiring to guard

against EMI (electromagnetic

interference).

Figure 12. Tank probe installation.

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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

WATER 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 26. 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 TOANY OPENING

NEAR BOTTOM OF TANK.

Figure 13. Single boiler with vertical tank.

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Gas Pipe sizing may be larger than heater connections on

installations where a significant run of piping is required. To prevent Where it is necessary to use more than the average number of

damage, care must be taken not to apply too much torque when pipe fittings i.e. elbows, tees, and valves in gas supply line, use

attaching gas supply pipe to gas inlet.

a pipe larger than specified to compensate for increased

pressure drop.

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

Gas control trains are unique for each Genesis II unit. Stages one,

two and three run sequentially left to right on the smaller units (GB/

GW 1000 -1500) while stage one is located in different positions on

the larger units. Gas manifold diagrams are depicted in Figure 14.

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

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

threads. Use compounds resistant to the action of liquefied

petroleum gases.

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.

WIRING CONNECTIONS

ALL ELECTRICAL WORK MUST BE INSTALLED IN

ACCORDANCE WITH THE NATIONAL ELECTRICAL CODE,

ANSI/NFPA 70 OR CSA-C22.1 CURRENT EDITION AND MUST

CONFORM TO LOCAL REGULATIONS.

2A. SIZING GAS SUPPLY LINE (For single boiler installations). See

Table 17.

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.

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

or more boilers). See Tables 15 (Natural Gas) and 16

(Propane Gas).

TABLE 17. SINGLE UNIT INSTALLATION, SUGGESTED

PIPE SIZE

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-C22.1 current edition.

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"

The Central Control Board and Flame 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. Refer to Connection and Schematic Diagrams.

See Figures 15 and 16.

2 1/2"

3 1/2"

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

2,100,000 2 1/2"

2,500,000 2 1/2"

3 1/2"

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.

4 1/2"

Use Tables 15 or 16, which are taken from ANSI booklet Z223.1,

NATIONAL FUELGAS CODE, or CAN/CSA-B149.1 (current edition)

to size iron pipe or equivalent gas supply line.

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

phase dedicated and isolated line source:120volts, 60Hz,and30Amps.

TABLE 18. Orifice Size for Natural and Propane (LP) Gases (U.S. and Canada Installations, for high altitude up to

4,500 ft. (1,372 m).

Drill Size

Input Rating

BTU/HR

Number of

Burners

Model

Natural (4 Holes)

Propane (3 Holes)

G(B,W) 1000

990,000

1,300,000

1,500,000

1,850,000

2,100,000

2,490,000

0.111"

0.075"

G(B,W) 1300

G(B,W) 1500

G(B,W) 1850

G(B,W) 2100

G(B,W) 2500

0.111"

0.075"

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GAS MANIFOLD ASSEMBLY

GB/GW 1850

GB/GW 1000 - 1500

GB/GW 2100

GB/GW 2500

Figure 14. GB/GW 1000 - 2500 Gas Manifold Assembly Diagrams.

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Figure 17. CCB CENTRAL CONTROL BOARD

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Figure 18. FCB FLAME CONTROL BOARD Diagram

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Figure 19. PDB POWER DISTRIBUTION BOARD Diagram

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Fuse Protection

(B.) Hot Water Supply Installation:

1. Close the systems drain valve.

The 24VAC circuitry is protected with a 3 amp fuse on the Flame

Control Boards (FCB) and a 7.5 amp fuse on the Central Control

Board. If the fuse opens, a red LED located near the fuse will light.

See Figures 17 and 18. 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 120VAC circuits of each Flame

Control Board is protected with a 10 amp (15 amp for the CCB)

fuse located on the Power Distribution Board (PDB). The 20 amp

pump fuse is also on the PDB.

2. Open a nearby hot water faucet to permit the air in the system

to escape.

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

and piping to be filled.

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

5. The heater is ready to be operated.

Recommended Replacement fuses:

Littlefuse automotive fuse p/n 29707.5 for the 7.5 amp

CCB fuse, and Littlefuse p/n 297003 for the 3 amp FCB fuses.

PURGING OF GAS LINE

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

air has entered.

OPERATION

CAUTION

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.

IMPORTANT

Only qualified personnel shall perform the initial firing of the heater.

If you have questions, please contact the factory or your local A.O.

Smith representative.

Operation and troubleshooting instructions are included with this

manual. By using these instructions, the user may be able to

make minor operational adjustments. The user should not attempt

repairs, but should contact a service technician or gas supplier

for service.

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.

GENERAL

WARNING

THE GAS VALVE MUST HAVE BEEN IN THE 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.

Never operate the boiler without first making sure the boiler and

system are filled with water, in addition:

For hot water supply Boiler installations:

• Make sure a temperature and pressure relief valve is installed

on the storage tank if used. Also check for leaks.

For heating boiler installations:

INLET GAS PRESSURE

•

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

and checked for leaks.

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. See Figure 14. The

maximum value specified in the table must not be exceeded. The

minimum values, shown in Table 19, must be maintained under

both load and no load conditions (static and firing conditions). 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.

FILLINGAND PURGING WATER SYSTEM

(A.) Hydronic Heating Installation:

1. Fill system through bypass until pressure approaches

desired system pressure. Close bypass valve and

permit pressure to be established by the pressure

reducing valve.

TABLE 19. INLET GAS PRESSURES.

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

INLET GAS PRESSURE

NAT. GAS PROP. GAS

MAX. INLET PRESSURE (IN. W.C.)

MIN. INLET PRESSURE (IN. W.C.)

14.0

6.0

14.0

11.0

Provisions should be made to permit manual venting of radiators or

convectors.

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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

•

IF YOU CANNOT REACH YOUR GAS SUPPLIER, CALL

THEFIREDEPARTMENT.

EQUIPPED WITH AN IGNITION DEVICE WHICH

AUTOMATICALLY LIGHTS THE BURNER. DONOT TRY TO

LIGHT THE BURNER BY HAND.

C. USE ONLYYOUR HAND TO PUSH IN OR TURN THE GAS

CONTROL KNOB. NEVER USE TOOLS. IF THE KNOB WILL

NOT PUSH IN OR TURN BY HAND, DON’T TRYTO REPAIR

IT. CALLAQUALIFIED SERVICE TECHNICIAN. FORCE OR

ATTEMPTED REPAIR MAY RESULT IN A FIRE OR

EXPLOSION.

B. BEFORE OPERATING: SMELLALLAROUND THEAPPLI-

ANCE AREA FOR GAS. BE SURE TO SMELL NEXT TO THE

FLOOR BECAUSE SOME GAS IS HEAVIER THANAIRAND

WILL SETTLE ON THE FLOOR.

WHAT TO DO IFYOU SMELL GAS

D. DO NOT USE THIS APPLIANCE 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 CONTROL WHICH HAS BEEN UNDER WATER.

E. DO NOT OPERATEAPPLIANCE UNLESS UNIT IS FILLED

WITH WATERAND WATER LINESARE FULLY OPEN.

•

DO NOT TRY TO LIGHT ANY APPLIANCE.

DO NOT TOUCH ANY ELECTRIC SWITCH; DO NOT

USEANY PHONE INYOUR BUILDING.

•

IMMEDIATELY CALL YOUR GAS SUPPLIER FROM A

NEIGHBOR’S PHONE. FOLLOW THE GAS SUPPLIER’S

INSTRUCTIONS.

Note: Knob cannot be turned to "OFF" unless

knob is pushed in slightly. Do NOT force.

OPERATING INSTRUCTIONS

STOP! READ THE SAFETY INFORMATION THE

NEXT STEP ABOVE ON THIS LABEL.

IF YOU SMELL GAS,

STOP ! FOLLOW “B” IN THE SAFETY INFORMA

TION ABOVE ON THIS LABEL. IF YOU DON’T

SMELLGAS, GO TO THE NEXT STEP.

2. SET THE SYSTEM CONTROLLER TO THE LOWEST

SETTING.

3. TURN OFF ALL ELECTRIC POWER TO APPLIANCE.

4. THIS APPLIANCE IS EQUIPPED WITH AN IGNITION

DEVICE WHICH AUTOMATICALLY LIGHTS THE

BURNER. DO NOT TRY TO LIGHT THE BURNER BY

HAND.

8. TURN TOP KNOB OF GAS CONTROL COUNTER

CLOCKWISE

TO “ON” POSITION, (FIG. B).

9. REPLACE CONTROLACCESS PANEL.

10. TURN POWER SWITCH TO “ON” POSITION.

11. SET THE SYSTEM CONTROLLER TO DESIRED

SETTING.

5. REMOVE CONTROLACCESS PANEL.

6. REFER TO DIAGRAMS ABOVE. TURN TOP KNOB OF

12. IFTHEAPPLIANCEWILLNOTOPERATE, FOLLOWTHE

INSTRUCTIONS “TO TURN OFF GAS TO THE

APPLIANCE” AND CALL YOUR SERVICE TECHNICIAN

OR GAS SUPPLIER.

GAS CONTROL CLOCKWISE

(FIGUREA).

7. WAITFIVE(5)MINUTESTOCLEAROUTANYGAS. THEN

SMELL FOR GAS, INCLUDING NEAR THE FLOOR.

TO “OFF” POSITION,

TO TURN OFF GAS TOAPPLIANCE

4. REFER TO DIAGRAMS ABOVE. TURN TOP KNOB OF

GAS CONTROL CLOCKWISE (TO “OFF” POSITION,

(FIGUREA).

1. SET THE SYSTEM CONTROLLER TO THE LOWEST

SETTING.

2. TURN POWER SWITCH ON APPLIANCE TO “OFF”

POSITION.

5. REPLACE CONTROLACCESS PANEL.

3. REMOVEACCESSPANELTOEXPOSEGASCONTROL.

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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.

• IF YOU CANNOT REACH YOUR GAS SUPPLIER, CALLTHE

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

FIREDEPARTMENT.

EQUIPPED WITH AN IGNITION DEVICE WHICH

AUTOMATICALLYLIGHTS THE BURNER. DO NOT TRYTO

LIGHT THE BURNER BY HAND.

C. USE ONLYYOUR HAND TO TURN THE MAIN MANUALGAS

VALVEHANDLE. NEVERUSETOOLS. IFTHEHANDLEWILL

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

QUALIFIEDSERVICETECHNICIAN. FORCEORATTEMPTED

REPAIR MAY RESULT INAFIRE OR EXPLOSION.

B. BEFORE OPERATING: 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.

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

ANYGAS 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 USEANYPHONE INYOUR 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 FULLY OPEN.

OPERATING INSTRUCTIONS

SMELLFORGAS, INCLUDINGNEARTHEFLOOR. IFYOU

SMELL GAS,

STOP! READ THE SAFETY INFORMATIONABOVE

ON THIS LABEL.

STOP! FOLLOW “B” IN THE SAFETY INFORMA-

TION ABOVE ON THIS LABEL. IF YOU DON’T SMELL

GAS, GO TO THE NEXT STEP.

2. SET THE SYSTEM CONTROLLER TO THE LOWEST

SETTING.

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 OUTANY GAS. THEN

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.

8. TURN POWER SWITCH TO “ON” POSITION.

9. SET THE SYSTEM CONTROLLER TO DESIRED SETTING.

10. IF THEAPPLIANCE WILL NOT OPERATE, FOLLOW THE

INSTRUCTIONS “TO TURN OFF GAS TO THE APPLI-

ANCE” ANDCALL YOUR SERVICE TECHNICIAN OR GAS

SUPPLIER.

TO TURN OFF GAS TOAPPLIANCE

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

(FIGURE “B”). THE VALVEIS “OFF” WHEN THE HANDLE

IS PERPENDICULAR TO THE GAS FLOW DIRECTION.

1. SET THE SYSTEM CONTROLLER TO THE LOWEST

SETTING.

2. TURN POWER SWITCH ON APPLIANCE TO “OFF”

POSITION.

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TABLE 20. RISK OF SCALDS.

MANIFOLD PRESSURE

TEMPERATURE

SETTING

TIME TO PRODUCE 2nd & 3rd

DEGREE BURNS ON ADULT SKIN

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.

OVER 170°F (77°C)

160°F (71°C)

NEARLY INSTANTANEOUS

ABOUT 1/2 SECOND

ABOUT 1-1/2 SECONDS

LESS THAN 5 SECONDS

ABOUT 30 SECONDS

MORE THAN 5 MINUTES

150°F (66°C)

IMPORTANT

140°F (60°C)

UNDER NO CIRCUMSTANCES SHALL THE GAS PRESSURE

MEASUREDAT THE 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.

130°F (54°C)

120°F (49°C) OR LESS

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.

ADJUSTMENTS

ON INITIAL STARTUP SOMEADJUSTMENTSARE NECESSARY.

1. CHECK MANIFOLDAND INLET GAS PRESSURES.

CONTROL SYSTEM

The EMC 5000 control system is a fully integrated, state of the art

electronic control system. It consists of sensors, output devices, a

power switch, a 24vac transformer, wiring and the following printed

circuit boards:

2. CHECK THE INPUT. SEE NATIONAL FUEL GAS CODE, ANSI

Z223.1 OR CAN/CSA - B149.1 (CURRENT EDITION) FOR

PROCEDURES.

DANGER

• Central Control Board (CCB), see Figure 17.

• Flame Control Board (FCB), see Figure 18.

• Power Distribution Board (PDB), see Figure19.

• User Interface Module (UIM), see Figure 21.

HOT WATER TEMPERATURES REQUIRED FOR AUTOMATIC

DISHWASHER AND LAUNDRY USE CAN CAUSE SCALD

BURNS RESULTING IN SERIOUS PERSONAL INJURY AND/OR

DEATH. THE TEMPERATUREAT WHICH 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. NEVERALLOW

SMALL CHILDREN TO USE A HOT WATER TAP, OR TO DRAW

THEIR OWN BATH WATER. NEVER LEAVEACHILD OR DISABLED

PERSON UNATTENDED INABATHTUB OR SHOWER.

The CCB contains circuitry for both master control and flame control

for the first stage. The FCB's contains circuitry for control on up to

three additional stages. Dipswitches on the CCB and FCB are used

to configure the system. The User Interface Module (UIM)

communicates with the user through a set of touch pads and a 4-

line, 20-character LCD display. The PDB provides connection points

for input power, the water pump, and the transformer. It also

distributes power to the system and contains the system fuses.

THE WATER HEATER SHOULD BE LOCATED INANAREAWHERE

THE GENERAL PUBLIC DOES NOT HAVE ACCESS TO SET

TEMPERATURES.

Multiple-stage control is accomplished by means of an internal

communications network between the CCB and the FCB's. One

FCB is required for each stage beyond the initial first stage. The

CCB also contains an external communications system to allow

for connection to a PC, a modem, an EMS system, or something

similar. Through this connection multiple boilers can also be linked

together. CAUTION: The internal communications cables should

never be connected to the external communications connectors

and vice-versa.

There are several microcontrollers used on the boards. These

micros control the temperature and ignition control functions for

the boiler. Inherent in the design are the normal operating

sequences and safety features associated with a gas ignition

control system. The system continuously performs various

diagnostic tests to verify proper appliance and control operation.

Should an unsafe condition occur, the control will shut down the

burner and display a red fault light as well as indicate the cause of

the fault on the display. The operating programs for the system are

IT IS RECOMMENDED IN DOMESTIC HOT WATERAPPLICATIONS

THAT LOWER WATER TEMPERATURES BE USED TOAVOID 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 WILLALSO PROVIDE THE MOST ENERGY

EFFICIENT OPERATION OF THE BOILER AND MINIMIZE SCALE

FORMATION IN THE HEAT EXCHANGER, THUS PROLONGING stored in permanent memory inside the micros. User-selectable

THE LIFE OF THE BOILER.

operating parameters and a history of detected faults are stored in

re-writable memory in the micros. A loss of power does not affect

SETTING THE WATER HEATER TEMPERATUREAT 120°F (49°C) either of the memories.

WILL REDUCE THE RISK OF SCALDS. SOME STATES REQUIRE

SETTINGS AT SPECIFIC LOWER TEMPERATURES. TABLE 20

ABOVE SHOWS THE APPROXIMATE TIME-TO-BURN

RELATIONSHIP FOR NORMAL ADULT SKIN.

Inputs to CCB and FCB

Temperature Sensors:

•

Temperature probes (CCB - outlet and either inlet or tank are

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required): The CCB accepts analog temperature inputs from up

to three sensors (inlet, outlet and tank).

ECO input (CCB - required):

the burner. If the flame rod is missing or shorted, the flame will

not be detected. This input is enabled/disabled by a dipswitch

on the FCB.

•

The ECO (energy cut off) is a hi-limit switch, which is located

inside the outlet probe. It is a normally closed switch that opens

if the probe is exposed to a temperature higher than the trip

point. Once tripped, control system needs manual reset.

Thermostat input (CCB - optional):

Outputs from CCB and FCB's:

Relay Contact Output:

•

IRI Gas Valve (CCB - 120 vac - optional):

This input is set up to work with an externally connected

thermostat that provides a contact closure. If this input is closed

and everything else is in the proper state, a "call for heat"

condition will be initiated. These leads should be shorted

together, when a thermostat is not being used. If it is desired

that the thermostat control the temperature of the boiler, the

operating setpoint of the system should be set higher than the

temperature that the thermostat is controlling to. This will allow

the thermostat to control the boiler. When the thermostat closes,

a call for heat will be generated until the thermostat determines

that the required temperature has been reached.

Provides electrical power to operate an IRI Gas Valve Device.

Alarm (CCB - 24vac - optional):

•

Provides electrical power to operate an external alarm. This

can be an audio device (i.e. Sonalert), a visual device (lamp),

or any other device that will operate with the voltage and current

level provided.

•

Pump (CCB - 120vac - required on systems that do not have

an external pump):

Provides electrical power to directly operate a pump or the coil

of an externally connected contactor.

•

Powered Vent (CCB - 24 vac - optional):

Air Pressure Sensors (open condition indicates fault):

Provides electrical power to operate a powered vent.

Blower (CCB / FCB - 120vac - required).

•

Blocked Flue (CCB - required):

Normally closed switch that opens if the flue becomes blocked

during operation.

Powered Vent (CCB - optional):

Normally open switch that closes when the powered vent is

operating properly. This input is enabled/disabled by a dipswitch

on the CCB.

Blower Prover (CCB/FCB - required on Stages with Blowers).

Normally open switch that closes when the air pressure

produced by the blower is above the set point.

Single speed blowers utilize the high blower output only. Dip

switches on the FCB's enable/disable the use of blowers on

stages 2, 3 and 4.

•

Igniter (FCB - 120vac - required).

Provides power to operate the HSI igniters. Dip switches on

the FCB's enables/disables the use of HSI igniters on stages

2, 3 and 4.

•

Gas Valve (FCB - 24vac - required):

Provides power to activate the gas valve. The gas valve cannot

be activated when the ECO contacts are open.

Low Water Cut Off (CCB - 24vac - optional)

Directly connected to the 24 vac line to provide power to operate

an external LWCO device.

Gas Pressure Sensors (open condition indicates fault):

•

Low Gas (CCB - required):

Normally open switch that closes when the gas pressure rises

above the trip level. This input is enabled/disabled by a dipswitch

on the CCB.

•

Hi Gas (FCB - optional):

CCB/FCB Indicator Lamps & Fuses

Normally closed switch that opens if the gas pressure exceeds

a set value. This input is enabled/disabled by a dipswitch on the

CCB and FCB's.

A green LED is mounted on the PDB to indicate when line voltage

is applied. (The PDB also contain a yellow and red LED, and a

test/run jumper, that are used during installation to verify proper

power connections.) A red LED on the CCB is used to indicate

when the 24vac input fuse has blown. The FCB's also have fuses

on their 24vac power line.

Water Level Sensor (open condition indicates fault):

•

Low Water Cut Off (CCB - optional):

Normally open switch that closes when water reaches preset

level. This input is enabled-disabled by a dipswitch on the CCB.

Yellow LED's are located near the micros on the CCB and

FCB's. These LED's are "heartbeat indicators" and blink

approximately twice per second to indicate that the micros are

running.

Water Flow Sensor:

•

Flow (CCB - required):

Normally open switch that closes when flow exceeds a set value.

CCB/FCB Jumpers:

IRI Gas Valve Sensor:

The CCB has two jumpers and the FCB has one. JP1 on the

CCB is used to terminate the external communications line. It

is normally left off and installed when the external cable is very

long. JP2 on the CCB and JP1 on the FCB, are for factory use

only.

•

IRI Gas Valve (CCB - optional):

Normally open switch that closes when the IRI Gas Valve is

operating correctly. This input is enabled/disabled by a dipswitch

on the CCB.

•

Flame Sensor:

Igniters

Flame (CCB - required).

Returns a signal to the microprocessor if flame is detected on The EMC 5000 system operates with Silicon Carbide Igniters.

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CCB - Ten Position Dipswitch (Central Control Section) SW1:

Dipswitch configurations are READ ONLY ON POWER UP. These switches are only to be set at the factory or by authorized trained

personnel! Once set the boiler will operate according to the chosen options. If a switch is changed, power must be cycled before the

change will take effect. The status of all dipswitches can be observed on the system status screen on the UIM.

CCB/FCB Dipswitches:

Switch Position

Dipswitches Function

Boilers

Water Heaters

Off = GW/LW

Off = 1

Switch 1: Selection of the type of boiler application:

Switch 2: Trials for ignition:

On = GB/LB

On = 3

Switch 3: IRI Gas Valve Option:

Switch 4: Controlling Probe:

On = IRI

Off = No IRI

Off = Inlet

On = Tank (Remote)

On = Yes

Switch 5: Powered Venter:

Off = No

Switch 6: Low Water Cut Off: (LWCO)

Switch 7: Low Gas Pressure

Switch 8: Spare:

Off = No

Switch 9 & 10. Number stages (FCB's):

Off

#stages

= 1

Off

= 2

= 3

= 4

NOTE: If the unit powers up with the number of stages selected by dip switches exceeding the number of FCBs, the CCB will detect

this condition and go into a hard lockout. After changing the dipswitches to the correct number of stages, the power must be

cycled on and off to accept the change.

Example of Dipswitch configuration:

GW model, 1 ignition trial, IRI, Tank Probe used, No Power Vent, No LWCO,

No Low Gas, 3 stages.

CCB - Three position Dipswitch (Flame Control Section) SW2:

This dipswitch is similar to the FCB dipswitches described below, but with only three switches being used: the number of blower

speeds (switch #3), Hi Gas option (switch #2) and a spare (switch #1). Only the blower speed and Hi Gas options are the required

selection, within the CCB . The FCB1 always has a blower, igniter, flame checking, and the address is always stage 1, see Figure 16.

Dipswitch Function:

Dipswitch Position

Switch 1: Spare:

Switch 2: Hi Gas pressure switch:

Switch 3: Number of Blower Speeds:

On = Yes

Off =

On = 1 speed,

Off =

2 speed

CCB-SW2

Example of Dipswitch configuration:

No High Gas, 1 blower speed.

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FCB: Eight-Position Dipswitch

The first three switches are similar to the switch setup of SW2 on the CCB. The remaining five switches are required for the function

of igniter, blower, flame detection, and to address the firing stage. NOTE: When switch 5 is set to OFF (no blower), switch 3 (blower

speed) is ignored.

Dipswitch Function:

Dipswitch Position

Switch 1: Spare:

Switch 2: Hi Gas pressure switch:

Switch 3: Number of Blower Speeds:

Switch 4: Igniter used:

On = Yes

Off =

On = 1 speed,

On = Yes,

Off =

2 speed

Switch 5: Blower used:

On = Yes,

Off =

Switch 6: Flame Checked:

Switch 7 & 8. Stage selection:

On = Yes,

Stage #

Off

Not allowed

*When switch 5 is in off (no blower) position, switch 3 (blower speeds) is ignored.

Example of Dipswitch configuration:

No High Gas, 1 blower speed, no igniter, no blower,

flame not checked, stage 4.

(yellow "Standby" LED on), unless a previously stored fault has

been recalled, which will send the system into the service model

(red "Service" LED on). In standby mode the display shows

the temperature screen and in fault mode the current error

screen is displayed.

Operating Sequence

NOTE: The following sequence is based on a three-stage system.

1. The EMC 5000 controller has four modes ofoperation: Initialization,

Standby, Running, and Service. The internal CCB and FCB micros

control these modes through a sequence of steps (or States) which

are further described in the "UIM Operating Procedures" section.

4. The system then compares the temperature read from the

controlling probe (inlet or tank) to the setpoint temperature. If

the temperature is less than the operating setpoint minus the

differential temperature and the thermostat input is closed then

a call for heat is established and the system shifts to the run

mode (green "Running" LED turns on).

2. When power is applied to the system, it enters the initialization

mode and the following automatic functions are performed:

•

A. O. Smith opening screen is displayed.

The system goes through a calibration indicated by the green

running LED blinking and then staying on; next the red service

LED and yellow standby LEDs come on, next the stage 1 service

and runnings LEDs blink ON and OFF followed by stage 2, stage

3, stage 4 and then back to stage 1, 2, 3, 4 LEDs.

Stored values are recalled from memory.

Configuration dipswitches are read.

Pending faults are recalled

Micros on all boards start running (indicated by a flashing

Yellow LED near each micro)

Input sensors are read

5. The heating sequence begins by applying power to the pump

and, if selected, the powered vent and the IRI gas valve.

6. After a few seconds the blowers are turned on for 30-second

pre-purge period of combustion chamber.

•

7. The stage one igniter is turned on.

8. After the igniter has reached a minimum of 2.8 amps, the gas

valve is energized to allow gas flow to burners.

•

FCB's are configurated with the number of ignition trials to run.

9. After an additional one second, the system checks the status of

the flame through the flame rod (sensor). If the flame is not

verified within 4 seconds, the gas valve is immediately shut off

3. After initialization is complete (approximately 10 seconds) the

system turns the green LED off and goes to the standby mode

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followed by 15-second inter-purge period, then the system

returns to step 7, if the "Trial for Ignition" dipswitch is set for

three (3) tries. If the dipswitch is set for one (1) trial, the system

will declare an error and boiler will require resetting the control.

Example 2. Temperature begins at 90 and rises to 150, see Figure

20B. At 100 both stages are on. (This is the case when a boiler is

first started and the controlling temperature is below the operating

setpoint minus all of the differential setpoints. At that time both stages

are turned on, in sequence from 1 to 2. At 130 stage 2 turns off. At

140 both stages are off.

10. If a flame is detected, stage two will be activated and start its

blower. Once the blower air has been proven, igniter two will

begin trial for ignition cycle as above, (this is not the case for

model 1000, which has only one igniter).

Stages 1 and 2 will turn on in sequence from 1 to 2.

11. Stage three will activate upon flame detection on stage two.

The gas valve will open five seconds following call for heat

and gas flow will continue if flame signal is detected. (On 4-

stage firing system, the blower associated with stage three

will start and once the blower air has been proven, the ignition

cycle will take place as above. If flame is not proven, a 15-

second inter-purge period will be activated followed by another

trial for ignition).

FIGURE 20 A.

FIGURE 20 B.

12. All stages will remain running until the set point for a given stage

is satisfied. The last stage will drop out first followed by inter-

stages then stage one will drop out last. Note: Once a stage is

satisfied, the blower associated with that stage will continue for

15-second post purge period.

UIM OPERATING PROCEDURES

13. Once all the stages have been satisfied, the boiler pump will

continue to run for the programmed post-circulate cycle.

14. The control now enters the idle state as displayed by the

"Standby" LED. The control will continue to monitor heat

demand and state of other system devices. Upon a drop of

water temperature below the set parameters, the control will

return to step 5 and repeat the entire operating cycle. Note:

Any fault detection, during standby or running modes, will halt

the heating sequence and shift the system to the service mode

where the detected fault will be displayed.

NOTE: In standby and running modes the system constantly

monitors the signals and the internal operation for faults. Any

detected fault will halt the heating sequence and shift the system

to the service mode, where the detected fault will be displayed.

FIGURE 21. UIM, USER INTERFACE MODULE

The UIM receives commands from the user and displays operational

information to the user via an LCD (liquid crystal display) up to

eleven LED's, and five touch switches. The LCD provides

information to the user by the use of 10 menu-activated screens.

Within each of the screens, helpful information can be displayed

by pressing the "Help" button. The LED's visually inform the user

about the mode the system is in. The touch switches allow the

user to control the operation of the system. The operation of these

parts is described in the following section:

Temperature Setpoints (System Control Algorithm)

The boiler has a hysteresis type control, which means that it will

begin heating the water when the temperature sensed by the control

probe (inlet or tank) falls below the operating setpoint minus the

differential setpoint for stage 1. It will stop heating the water when

the temperature rises to the operating setpoint. If the system has

multiple stages then the differential setpoint for each stage is also

subtracted from the operating setpoint. The following examples

will further explain this operation.

UIM Screens:

On all screens a double vertical bar appears on the right side of the

display each time a key is touched to indicate that a key has been

activated. On several screens an indicator ">" appears on the left

side of the display to indicate the active line. The "Up/Down" keys are

used to move the indicator to the desired line and the "Select" key is

pressed to select the line. Also, on most of the screens, up/down

arrows appear on the right side of the screen to indicate that there is

additional lines either above or below the displayed four lines.

Setup: 2 stage system, operating setpoint - 140, stage 1 to 2

differential setpoints = 10.

Example 1. Temperature begins at 150 and drops to 90, see Figure

20A. At 140 the system remains in idle mode. As the temp drops to

130 (140-10) stage 1 turns on and stage 2 remains off. At 120 stage

2 also turns on.

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The following status information is displayed from the System Status Screen:

Status Displayed

*(True Condition)

Input

Output

ECO

Outlet temperature too high

Water Level low

Flue blocked

Water flowing

Gas pressure low

Thermostat requesting heat

Outlet temp exceeds High Limit setpoint

Pump output activated

open

closed

open

closed

- - - -

LW/CO

Blk Flue

Flow

Low Gas

Tstat

Hi Limit

Pump

- - - -

IRI Gas Pwr

IRI Gas

Pwr Vent

Alarm

IRI output relay activated

IRI Gas Valve on

Power Vent running

- - - -

closed

- - - -

Alarm output activated

Pwr Vent Pwr

Power Vent output relay activated

- - - - STAGES 1 to 2 - - - -

Blower pressure sufficient

Blower High output activated

Blower pressure sufficient (not used at this time)

Blower low output activated (not used at this time)

Igniter current sufficient for ignition

Igniter output is activated

Gas output relay activated

Gas pressure too high

- - - -

BlwHi Prv

Blw Hi

BlwLo Prv

Blw Lo

Ignt Cur

Ignit

Gas Relay

Hi Gas

Flame

closed

- - - -

closed

- - - -

open

- - - -

Flame detected

after the Igniter is turned on until the igniter is turned off and an

off condition at all other times.

Flame - for an on condition approximately 5 seconds after the

gas valve is turned on until the valve is turned off and at all other

times for an off condition.

•

Menu Screen:

Displayed when the user presses the "Menu" key. This screen is

the selection point for the other 9 screens.

•

Temperature Screen:

Displays the sensed temperatures of the Outlet, Inlet, and Tank

probes. Also displayed is the calculated Delta T (Outlet minus

Inlet) for the system. Shorted ("Short") and disconnected ("----")

probes are also displayed.

Control Status Screen:

Displays the status that the CCB and FCB micros are in. The CCB

has 5 possible states and the FCB's have 9. The normal CCB states

sequence is to move from Idle, to Pre-Circulate, then to Heating

Stage 1-2-3-4 when a call for heat is initiated. Once heat has been

satisfied or the Thermostat is opened, the sequence moves to Post-

Circulate and then back to Idle. If a fault occurs at any time, the

process jumps out of sequence and goes directly to the appropriate

Hard or Soft Fault state.

•

System Status Screen:

This screen is used to view the status of switch inputs and output

states. An asterisk (*) is displayed next to the label when the

status is "True" (the description is fulfilled). For example, if water

is flowing, or detected by the flow sensor, then an "*" will appear

in front of the Flow label (i.e. *Flow). Another example would be

the ECO switch. If the outlet temperature is too high the display

will show: *ECO.

Description of CCB control states:

•

Idle:

The yellow "Standby" LED is turned on and the system waits for

a heat request (determined by the Thermostat or controlling probe

inputs). All outputsareoff in this stateexceptthatifthe Post-Circulate

time isset to continuous, the pump will be on. When the heat request

is received, the system moves to the Pre-Circulate state.

Pre-Circulate:

NOTE: The LWCO, IRI Gas Valve, Powered Vent, High Gas, and

Low Gas inputs are optional inputs. Flame sensing, Igniters, and

Blowers are optional on Stages 2, 3 and 4. (Except on a 4-stage

system, stage 2 always has an Igniter, Blower, and Flame Sensor.

Those dipswitches on stage 2 are not relevant.) One or two speed

blowers can be used on any stage.

•

The yellow LED is turned off and the green "Running" LED is

turned on. The green LED will remain on for all other states

except the fault states. If enabled the powered vent and the IRI

gas valve are turned on. A command is sent to all active stages

to cold purge the system. Cold purging clears out any

combustion gas that may be in the combustion chamber. When

purging is complete the system moves to the Heat State.

Heat Stages 1-2-3-4:

The System monitors the inputs at these times:

•

ECO, LWCO, Blocked Flue, Low Gas, Hi Limit, and Hi Gas - at all

times for a fault condition.

Tstat - at all times for open/closed conditions.

IRI Gas and Powered Vent - for an on condition when their outputs

(Pump, IRI Gas Pwr, Powered Vent Power) are turned on and an

off condition at all other times.

Flow-for an on condition when the pump is on (no check for off state)

Blower Prover - when the Blower is on.

•

The system will command the FCB micros to start their heat

sequence starting with stage 1. Stage 2, 3, 4 will be activated in

order based on an algorithm that determines how much heat is

needed. The system will remain in this state until the heat request

is satisfied, the Tstat is opened, or a fault occurs.

•

Igniter Current - for an on condition approximately 18 seconds

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•

Soft Fault State: (See "Fault Description" section for list of soft

and Auto Reset faults.)

that the gas valve relay is on. If it is not, the ignition trial is

considered to have failed and the system advances to the Inter-

Purge state, if any ignition trials remain, otherwise an error is

declared.

The CCB turns off the Powered Vent and the IRI Gas. The pump

remains on for the selected post-circulate time to cycle the hot

water out of the boiler. The FCB's are commanded to shut down

and the Alarm output is turned on. The green LED turns off and

the red "Service" turns on. The CCB remains in this state until

one of the following occurs:

The flame sensor is checked. If flame is detected, the igniter is

turned off. The state machine then advances to the Heating

State. If after 5 seconds, the flame is still not sensed then the

ignition trial is considered to have failed. The state machine

advances to Inter-Purge if any ignition trials remain, otherwise

an error is declared.

• One hour passes (automatic restart after one hour)

• If Communications error system will automatically

restart if communications re-establishes.

•

Heating State:

• If user presses Select key while current error screen is

displayed (Hard reset).

• If high-limit error - the outlet temperature drops below the high

limit trip point minus the high limit differential. (outlet water

temperature drops to safe level). The fault is logged in the

error history when the fault state is exited.

• Hard Fault State: (See "Fault Description" section for list of

soft and Auto Reset faults.) The CCB turns off the Powered

Vent and the IRI Gas. The pump remains on for the selected

post-circulate time to cycle the hot water out of the boiler. The

FCB's are commanded to shut down and the Alarm output is

turned on. The green LED turns off and the red "Service"

turns on and off (flashes). The only way to exit this state is for

the user to press the Select key while the current error screen

is displayed. The fault is logged in the error history when the

fault state is exited.

The system remains in this state until the call for heat is cancelled

or a fault occurs. The system returns to the Idle state if the call

for heat is cancelled, or satisfied and to the appropriate fault

state if a fault occur.

•

Inter-Purge State:

The gas valve and the igniter are turned off. The blower is on.

After approximately 15 seconds the system goes back to the

Heating Igniter State.

Post-Purge State

The gas valve and the igniter are turned off. If this stage does

not have a blower the system returns to the idle state. If it does

have a blower then the blower is left on. After approximately 25

seconds, the system returns to the Idle state.

•

Error State

While the CCB is in the Heating mode the activated FCB stage

moves from Idle, to Pre-Purge, to Heat Igniter, to Check for Flame,

and then to Heating. The process waits in this state until the call for

heat is satisfied, the thermostat input is opened, or a fault occurs.

When heat is satisfied, the sequence continues to Post-Purge and

then back to Idle. If three tries for ignition has been selected on the

CCB dipswitch and flame is not detected at the appropriate time,

then the sequence moves to the Inter-Purge state for 15 seconds

and the FCB heat sequence is repeated. If flame is still not detected

after the third try the process declares a fault, jumps out of sequence

and goes to the error state. Other types of faults detected at any

time will also cause a jump to the error state.

The gas valve and the igniter are turned off. The FCB micro tells

the CCB micro which error has occurred. The system waits in

this state until the CCB sends a command to clear the error, and

the system returns to the idle state.

Cold Purge State

Cold purge occurs when the CCB micro commands all blowers

to go on before lighting the first stage to clear the unit of residual

gases. This state normally lasts approximately 32 seconds but

on a special situation can last up to 5 minutes. If on the first call

for heat after power up, blower prover switch is open, this state

will take up to 5 minutes before declaring an error. This special

mode is used by service technicians to adjust the blower shutter.

Description of FCB control states:

•

Idle State:

The CCB will wait the normal cold purge time (normally 32

seconds) before checking for activation of all active blower prover.

If blower prover is active at this time the CCB cancels the cold

purge request. After the first cold purge has been done a flag is

set to prevent further activation of the shutter adjust 5 min. delay.

Any further requests for cold purge will last the normal cold

purge time. The FCB will go into fault mode if the blower prover

does not activate after 15 seconds. This time allows the blower

relay to activate, the blower to come up to speed, and the

response from the blower prover to be filtered.

When any error is declared during idle state-The system will

remain in this state until the CCB request a heating cycle, or a

cold purge.

•

Pre-Purge State:

If the stage does not have a blower, this state is skipped and the

system advances to the Heat Igniter State. Otherwise the Blower

is turned on. After 10 to 34 seconds (34 seconds for cold

purging) the system switches to the Heat Igniter State.

Heat Igniter State:

•

The sequence of operation is as follows: "The igniter relay is

energized and the heat up period begins. After 18-20 seconds,

if the igniter has reached a minimum of 2.8 amps, the gas valve

safety circuit is then activated. If in this amount of time, the igniter

fails to reach a minimum amp draw of 2.8 amps, the unit will re-

cycle up to 3 times before locking out on igniter hardware failure.

If the igniter does reach the minimum required amp draw of 2.8

amps, the gas valve circuit is energized, and the system

advances to Flame Check status.

•

User Settings Screen:

Each setpoint or user setting has either a limited selection of

values, or a limited range of values. The Up/Down keys are

used to change values. After changing an item, the Select key is

pressed to accept the change, or the Menu key is pressed to

reject the change and restore the item to its original value. The

following setpoints can be changed:

Operating Setpoint:

•

Check for Flame State:

The gas valve is turned on. After 1.5 seconds, the system checks

This setpoint sets the base temperature for the control algorithm.

See Figures 20A & 20B.

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6. Use the UP or DOWN key to select the value you wish to enter.

7. Touch the SELECT key to accept and store the new value.

OPERATING SETPOINT ADJUSTMENT PROCEDURE

The system has a standard programmable Operating Setpoint range

of 70 Degrees F to 190 Degrees F for a GW and of 70 Degrees F to

220 Degrees F for a GB for either tank or inlet probe depending on

selection. The user can easily change the Operating Setpoint at any

time by using the following procedure. When any configuration or

setpoint is changed (and the Select key touched), the new value is

IMMEDIATELY saved to non-volatile memory. The factory default

setting is 120 Degrees F.

•

Operating Differential Setpoints:

Each of the two stages has an independent Operating

Differential setpoint.

OPERATINGDIFFERENTIALSETPOINT

ADJUSTMENT PROCEDURE

Each of the two stages has an independent Operating Differential

Setpoint. The range of these setpoints is from 1 Degree F to 50

Degrees F for all models. Use the following procedure to change

this setpoint:

1. Touch the MENU key.

2. Scroll the ">" with the DOWN key next to the USER SETTING

SCREEN.

1. Touch the MENU key.

3. Touch the SELECT key.

2. Scroll the ">" with the DOWN key next to USER SETTING

SCREEN.

4. Scroll the ">" with the DOWN key until it is pointing to OPERATING

SETPOINT.

3. Touch the SELECT key.

5. Touch the SELECT key.

4. Scroll the ">" with the DOWN key until it is pointing to OPERATING

DIFFERENTIAL SETPOINT.

6. Use the UP or DOWN key to select the value you wish to enter.

7. Touch the SELECT key to accept and store the new value.

5. Touch the SELECT key.

6. Scroll the ">" with the DOWN key until it is pointing to the STAGE

you want.

•

High Limit:

The outlet temperature probe contains both an ECO switch and

a thermistor for temperature measurement. The sensed outlet

temperature is used for the automatically resettable High Limit

setpoint. If the sensed outlet temperature exceeds the High

Limit setpoint, a "soft lockout" condition will occur and the burner

will be shut off. This fault condition is automatically cleared

when the temperature drops below the high limit setpoint minus

the high limit differential.

7. Touch the SELECT KEY.

8. Use the UP and DOWN key to select the value you wish to enter.

9. Touch the SELECT key to accept and store the new value.

•

Temperature Units:

Temperature can be displayed in either °F or °C units.

•

Post Circulate Delay Time:

AUTO HIGH LIMIT SETPOINT ADJUSTMENT PROCEDURE/

OUTLET TEMP. PROBE

The High Limit setpoint has a range of 90 Degrees F to 210

Degrees F for a GW and a range of 90 Degrees to 235 Degrees F

for a GB. Use the following procedure to change the automatically

resettable High Limit Setpoint:

The time circulation pump will stay on after the burner is turned

off. The time in seconds is adjustable with the following values:

45, 90, 180 or continuous. If the continuous value is selected

the pump will remain on at all times and the post circulate state

time will be set at 45 seconds.

•

Network Address:

This is a unique number assigned to this boiler to differentiate

it from other boilers or water heater on the same A. O. Smith

proprietary network. Avalid Network Address can be any number

from 1 to 31. It is set by default to zero, which is an invalid address.

The boiler will not communicate until it is changed to a valid and

unique number. This prevents two units from trying to respond to

the same request from the PC or supervisory network device.

1. Touch the MENU key.

2. Scroll the ">" with the DOWN key next to USER SETTING

SCREEN.

3. Touch the SELECT key.

4. Scroll the ">" with the DOWN key until it is pointing to HIGH LIMIT

SETPOINT.

•

Configuration Settings Screen:

Displays the status of the dipswitches installed on all boards

as described earlier.

5. Touch the SELECT KEY.

6. Use the UP and DOWN key to select the value you wish to enter.

7. Touch the SELECT key to accept and store the new value.

Log & System Info Screen:

Displays the following information:

•

High Limit Differential:

Elapsed hours of operation (Total time system has been

powered up)

Number of running minutes (Number of minutes system has

been in the run mode)

The outlet temperature must be below the automatic High Limit

setpoint minus the High Limit Differential setpoint before a call

for heat can be generated.

HIGH LIMIT DIFFERENTIAL SETPOINT

ADJUSTMENT PROCEDURE

Number of cycles for each stage (Number of times stage has

been in heat mode).

kBtu rating of the boiler (0 to 5750kBtu in 10kBtu increments)

The software revision level of the CCB, and FCB

microcontrollers.

The High Limit Differential Setpoint has a range of 1 Degree F to 50

Degrees F for all models. Use the following procedure to change

the High Limit Differential Setpoint:

Current Error Screen:

•

Displays the last error that the system has detected plus a time

stamp of when the error occurred. (The time stamp is based on

the elapsed hours value at the time the error occurred. It is

displayed in hours and minutes. This error remain displayed

as long as it is still valid. When cleared it is moved to the Error

History Screen. The system will automatically jump to this screen

1. Touch the MENU key.

2. Scroll the ">" with the down key next to USER SETTING SCREEN.

3. Touch the SELECT key.

4. Scroll the ">" with the DOWN key until it is pointing to HIGH LIMIT

DIFFERENTIAL SETPOINT.

5. Touch the SELECT key.

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•

Up and Down Keys:

when an error is detected. It will also go to this screen upon

power-up if an error was still valid when power was turned off.

These keys are used to move upwards and downwards in

screens to reach a desired item and to change setpoints and

user settings. They have an auto increment/decrement feature

for some of the configurations and values. When you first press

one of the keys and value changes by 1 count, then wait 1/2

second and changes slowly until the key is released or if held

for 3 or more seconds it will change the value quickly.

NOTE: Errors are cleared from this screen by pressing the

"select" key.

•

Error History Screen:

This screen displays a list of the last 9 errors (with time stamps)

that have occurred. The last error to occur is displayed first. If a

new error occurs this screen is presented to display the error.

•

Help Key:

Reload Defaults Screen:

Pressing the Help key from any screen displays helpful

information about that screen. From the menu screen, general

help information is displayed as to how to use the user interface.

To return to the previous screen press the Help or Select keys,

or press Menu key to go to the menu screen. If a small down

arrow appears in the lower right hand corner then there is off

screen content below what is displayed. Press the down arrow

to scroll down to this information. After scrolling down an up

arrow will appear in the upper right hand corner to indicate off

screen content above what is displayed.

From this screen the user can restore the factory default values

for screen adjustable configurations by pressing the Select key.

The values restored are as follows:

GW Models

Oper Setpnt (Operating Setpoint) - 145° F (63° C)

Stage1 Diff (Operating Setpoint Differential) = 3° F (2° C)

Stage2 Diff (Operating Setpoint Differential) = 6° F (3° C)

Hi Limit (High LImit Setpoint) = 210° F (99° C)

Hi Limit Dif (High Limit Differential) = 20° F (11° C)

UIM LED's

GB Models

The three LED's to the right of the LCD indicate the status of the

overall system. The red LED indicates that a fault has been detected

and the system has stopped running. It is on continuously for soft

faults and flashes for hard faults. The Yellow LED indicates that

the boiler is in a ready mode waiting for a call for heat command.

When on continuously the Green LED indicates that the system is

in the heating mode. If it is flashing it indicates that the UIM is in the

initialization mode and the touch switches are being calibrated.

Oper Setpnt (Operating Setpoint) = 190° F (88° C)

Stage1 Diff (Operating Setpoint Differential) = 3° F (2° C)

Stage2 Diff (Operating Setpoint Differential) = 6° F (3° C)

Hi LImit (High LImit Setpoint) = 230° F (110° C)

Hi Limit Dif (High Limit Differential) = 20° F (11° C)

Both Models

Tempert Units (Temperature Units) = F

Post Cir Secs (Post Circulation pump delay = 45 seconds

Network Address (Network Address) = (none)

On these boilers there are also eight LED's on the lower right that

indicate the state of the individual FCB's. The red LED's are only on

when the main red LED is on and indicate which FCB has the error.

The green LED indicates when flame is proved on that particular

stage, unless the dipswitch for sensing flame is turned off. Then

the LED indicates that the gas valve has turned on.

UIM Touch Switches

Below the LCD display are five touch switches or keys, that the

operator uses to operate the system.

•

Menu Key:

Pressing this key activates the menu screen where the other

screens can be accessed.

Select Key:

This key performs several functions. Screens can be selected

from the menu screen by pressing this key when the">" appears

next to the screen desired.

Fault Messages and Troubleshooting Guide

The EMC5000 system does excessive self-diagnostics and

displays detected faults on the UIM display in an easy to read

manner. There are approximately 80 different faults that can be

detected. Some of the faults are caused by internal problems and

some by external causes. The faults create different types of system

lockouts (shut down). Hard lockouts are serious problems that

require the user to manually restart system. Soft lockouts can be

reset by the user or after 60 minutes the system will automatically

clear the error and restart. Auto Reset lockouts will monitor the

cause of the fault and if the fault clears itself the system reset itself.

The fault is recorded and the system immediately resets itself.

The following table shows the fault messages and some possible

troubleshooting hints:

On the User Settings screen items that appear next to a ">"

symbol can be selected with this key. If a setpoint configuration

item is selected, the ">" will then flash slowly to indicate that the

item has been selected. The Up and Down keys are then used

to change its value.

From the Current Error Screen this key is used to reset the

system from an error:

TROUBLESHOOTING IGNITION SYSTEM

Fault Messages and Lockout Status (* = stage number: 1, 2, 3, or 4)

FAULTDISPLAYED

DESCRIPTION

REDLED

Continuous

LOCKOUT

“Display Fail”

Communications with UIM interrupted

Auto Reset

Check communication cable to UIM. Try moving to other Internal Communications connector on CCB.

Also check the connectors where the cable is plugged in for best connecting wires.

“Comm. Fail Stg.*”

“Low AC Voltage”

Communications with FCB interrupted

Same as above. Also try swapping FCB and UIM communications cables.

Line voltage less than 90 vac Continuous

Continuous

Auto Reset

Check incoming power line for loss of voltage. May also be caused by a power line brown-out (momentary

loss of voltage)

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“Low 24VAC”

Voltage from transformer less than 18 vac

Check transformer output. Should be over 24vac. May be caused by

excessive current drain or a faulty transformer

Continuous

- - - -

Auto Reset

None

“Brown Out Reset”

“Timeout Reset”

Indicates a brown out reset occurred

Caused by a momentary dip in voltage on the CCB +5vdc power bus. Contact factory. (Not considered a

serious problem if it only occurs on very rare occasions.)

Indicates a watchdog reset occurred

- - - -

None

Caused when the micro executes the software in an improper way. Contact factory. (Not considered a

serious problem if it only occurs on very rare occasions.)

“FCB Comm Timeout” FCB did not receive command from CCB

Continuous

SOFT

Caused when communications between the CCB and the FCB are interrupted. May occur when a surge of

power on a nearby device (i.e. arc welder) creates an EMI burst. Not a serious problem if it occurs rarely.

“No Flow”

Water is not flowing

Continuous

SOFT

Caused by the flow switch being open when it should be closed. Check water lines, pump, flow switch

contacts, wiring.

“Blower Prov Stg*

“Blocked Flue”

Blower pressure is too low it they should have been closed.

Check blower, switch contact, wiring, and for air leaks.

Continuous

SOFT

Flue is Blocked

Continuous

SOFT

Caused by the blocked flue switch contacts being open when they should have been closed. Check for flue

blockage, switch contacts, wiring.

“High Limit”

“ECO fault”

Outlet temp. exceeded high limit setpoint

Continuous

Auto Reset

Caused when the temperature of the outlet probe exceeds the high limit setpoint. This is an internal

“software” limit switch and not an actual device. Check that the over temperature is not being caused by

improper setup or operation of the boiler.

Outlet temp is too high

Flashing

HARD

Caused when the ECO (a thermostat) contacts in the Outlet probe are open when they should be closed.

Fault may be due to high outlet temperature, bad switch contacts in the ECO, or disconnected wiring. Note:

The ECO can be checked by disconnecting the outlet probe from the CCB and reading the resistance

across the two active pins on the connector at the end of the probe cable. The value should be approximately

0 ohms when the temperature of the probe is less than 220°F.

“Low Water”

“Low Gas”

Water level is too low

Flashing

HARD

Caused by the Low Water Cut Out device not closing its feedback switch contacts when it should. Check

water line, switch contacts, wiring, LWCO.

Gas pressure is too low

Flashing

HARD

Caused by the Low Gas switch being open when it should be closed. Check gas line, switch contacts,

wiring.

“IRI Gas”

IRI Gas Valve did not turn on

Flashing

HARD

Caused by the IRI Gas Valve not closing its feedback switch contacts when it should. Could also be caused

by a problem with the relay output on the CCB. Check output to IRI Gas Valve, switch contacts, wiring.

“Powered Vent”

Power vent not running

Flashing

HARD

Caused by the Powered Vent device not closing its feedback switch contacts when it should. Could also be

caused by a problem with the relay output on the CCB. Check output to powered vent, switch contacts, wiring.

“High Gas Stg*”

“Inlet Probe”

Gas pressure too high

Flashing

HARD

Caused by the High Gas switch being open when it should be closed. Check gas line, switch contacts, wiring.

Inlet probe shorted or open Flashing HARD

Caused when the thermistor in the probe or the wiring to the probe is shorted or disconnected. Check the

probe. Note: The thermistor and wiring can be checked by disconnecting the probe from the CCB and

reading the resistance across the two active pins on the connector at the end of the probe cable. The value

should be approximately 10K ohms (value will change slightly with changes in temperature).

“Outlet Probe:”

Outlet probe shorted or open

Flashing

HARD

Caused when the thermistor in the probe or the wiring is shorted or disconnected. Check the probe. Note:

the thermistor and wiring can be checked by disconnecting the probe from the CCB and reading the

resistance across the two active pins on the connector at the end of the probe cable. The value should be

approximately 10K ohms (value will change slightly with changes in temperature).

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“Tank Probe”

Tank (Remote) probe shorted or open

Flashing

HARD

Caused when the thermistor in the probe or the wiring is shorted or disconnected. Check the probe. Note:

the thermistor and wiring can be checked by disconnecting the probe from the CCB and reading the

resistance across the two active pins on the connector at the end of the probe cable. The value should be

approximately 10K ohms (value will change slightly with changes in temperature).

“Igniter Stg*”

Igniter current is too low

Flashing

HARD

Caused by a low current draw problem with the igniter. This may occur if the igniter is old, damaged, or

disconnected and no longer draws the proper level of current. This condition will affect the ability of the

igniter to get hot enough to fire the gas properly. Check the igniter and its associated wiring.

“Igniter Pwr Stg*”

Improper power applied to the igniter circuit

Flashing

HARD

Caused by improper line power being applied to the igniter circuitry. Check line connections.

Paying particular attention to the earth ground connection. Also check that line voltage does not exceed 132

vac rms.

“Igniter Hdwr Stg*”

Hardware problems with igniter circuit

Flashing

HARD

3. Check that burner venturi and ports are free of foreign matter.

PREVENTATIVE MAINTENANCE

4. Clean burners with bristle brush and/or vacuum cleaner. DO NOT

distort burner ports.

This is an induced burner and the flame is not supposed to be directly

on the burner. The flame should be just above the burner deck

approximately 1/8” and blue in color. See Figure 22.

5. 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 23.

Visually check flame characteristics through the view port located

under the left-hand header on the boiler. Figure 22 shows the

normal flame condition. Also, refer to the flame label on the unit

(adjacent to the view port).

These boilers are designed to give many years of efficient and

satisfactory service when properly operated and maintained. 6. Also check for good flow of combustion and ventilating air to

the unit.

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:

Figure 22. Normal Flame Characteristics

•

Provide complete combustion of gas.

Cause rapid ignition and carry over of flame across entire burner.

Give reasonably quiet operation during initial ignition, operation

and extinction.

•

Cause no excessive lifting of flame from burner ports. See Figure 22.

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. To check burners:

1. Shut off all gas and electricity to unit. Allow unit to cool.

2. Remove main burners from unit.

Figure 23. Orifice Insertion

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After placing the boiler in operation, check the ignition system safety any dirt and lint that may have accumulated in the compartment or

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.

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.

VENTINGMAINTENANCE

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.

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

INSTALLATIONS in the installation section. See page 5.

THE FLOW OF COMBUSTIONAIR TO THE BOILER MUST NOT BE

OBSTRUCTED.

WARNING

DO NOT USE A NYLON BRUSH OR OTHER STATIC CREATING

MATERIAL TO CLEAN DUST AND CARBON DEPOSITS FROM

HEATING SURFACES AND VENT. SUCH DEPOSITS ARE

FLAMMABLE AND MAY BE IGNITED BY STATIC ELECTRICITY.

USE A METAL BRUSH TO MINIMIZE THE DANGER OF

EXPLOSION.

THE BOILER AREA MUST BE KEPT CLEAR AND FREE FROM

COMBUSTIBLE MATERIALS, GASOLINEAND OTHER FLAMMABLE

VAPORSAND LIQUIDS.

Any safety devices including low water cutoffs used in conjunction

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.

Qualified serviceman should follow this procedure when the boiler's

intake and exhaust piping need cleaning:

1. Turn off the electrical power, and manual gas shut-off.

• Allow boiler parts to cool before disassembly.

More frequent inspections may be necessary depending on water

conditions.

2. Remove the vent pipe.

• Check parts and chimney for obstructions and clean as

necessary.

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.

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

to clean as necessary.

• Refer to parts list for disassembly aid.

RELIEFVALVE

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.

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.

5. Restore electrical power and gas supply to boiler.

• Check for gas leaks and proper boiler and vent operation.

DANGER

HEATEXCHANGERPREVENTIVEMAINTENANCE

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.

In most water supply systems 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.

WARNING

CAUTION

SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAILTO

SHUT OFF, TURN OFF THE MANUAL GAS CONTROL VALVE TO

THEAPPLIANCE.

LIME ACCUMULATION CAN REDUCE THE LIFE OF THE

EQUIPMENT, REDUCE EFFICIENCYAND WASTE FUEL. BOILER

FAILURE DUE TO LIME OR SCALE BUILDUP VOIDS THE

WARRANTY.

COMBUSTIONAIR FILTER

DELIMING

If the combustion air supply to the boiler contains dust, dirt, drywall

dust etc. a filter must be installed. An 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. Periodically clean

air filter per the manufacturer's instructions.

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.

BLOWER COMPARTMENT

The usage of water softening equipment greatly reduces the

The blower compartment should be cleaned annually to remove hardness of water. However, this equipment does not always remove

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all of the hardness (lime). For this reason it is recommended that a

regular schedule for deliming be maintained.

CAUTION

IF HEAT EXCHANGER MAINTENANCE REQUIRES TUBING

REPLACEMENT, SPECIAL PROVISIONS SHALL BE TAKEN TO

ENSURE THAT THE DAMAGED TUBES ARE CAREFULLY REMOVED.

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.

REPLACEMENT TUBES MUST BE PROPERLY INSTALLED AND

EXPANDED INTO THE ROLLED TUBE TUB.

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.

TUBECLEANINGPROCEDURE

MECHANICAL REMOVAL OF DEPOSITS

REPLACEMENT PARTS

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.

Replacement parts may be ordered through A. O. Smith dealers,

authorized servicers or distributors. Refer to the Yellow Pages

for where to call or contact (in United States) the A. O. Smith

Water Products Company, 500 Tennessee Waltz Parkway,

Ashland City, TN 37015, 1-800-433-2545 or (in Canada)

A. O. Smith Enterprises Ltd., 768 Erie Street, Stratford,

Ontario, Canada N5A 6T3, 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 (P/N 212513-000) for more information.

To service heat exchanger tubes, remove return header casting

on the side opposite the water connections. Use a U.S. standard

5/8" deep socket ratchet to remove the nuts, exposing the tube

ends. Inspect to ensure tubes are free of scale and deposits.

If scaled, remove deposits with a stiff wire brush or mechanical

tube cleaner to bare metal. Reinstall return header casting.

Flush system.

For Technical Assistance call A. O. Smith Technical Information

Center at 1-800-527-1953.

Note: Removal of the heat exchanger is not required.

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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;

(7) in properly sized piping system in accordance with A.O. Smith WPC sizing guidelines.

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

A. O. Smith Water Products Company

500 Tennessee Waltz Parkway

Ashland City, TN 37015

Canadian Customers

A. O. Smith Enterprises Ltd.

P. O. Box, 310 - 768 Erie Street

Stratford, Ontario N5A 6T3

Telephone: 800-265-8520

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 WARRANTYHAS BEEN OR WILLBE MADE ON BEHALF OF THE WARRANTOR WITH RESPECTTOTHE MERCHANTABILITYOF

THE BOILER ORTHE INSTALLATION, OPERATION, REPAIR OR REPLACEMENTOF THE BOILER. THE WARRANTOR SHALLNOT BE RESPONSIBLE

FOR WATER DAMAGE, LOSS OF USE OFTHE UNIT, INCONVENIENCE, LOSS OR DAMAGETO PERSONALPROPERTYOR OTHER CONSEQUENTIAL

DAMAGE. THE WARRANTOR SHALL NOT BE LIABLE BY VIRTUE OF THIS WARRANTY OR OTHERWISE FOR DAMAGE TO ANY PERSONS OR

PROPERTY, WHETHER DIRECTOR 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_____________________________________________________________________________________________________________________

InstallationAddress___________________________________________________________________________________________________________

City and State or Province____________________________________________________Postal/Zip Code____________________________________

Date Installed__________________________Model No.______________________________Serial No.________________________________________

Dealer’s Name_______________________________________________________________________________________________________________

Dealer’sAddress________________________________________________________________Phone No. ____________________________________

FILLIN WARRANTYAND KEEPFOR FUTURE REFERENCE

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500 Tennessee Waltz Parkway, Ashland City, TN 37015

Phone: 800-433-2545

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

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