A.O. Smith 2500 manual

1 PRINTED IN U.S.A. 2526 0501 COPPER BOILERS FOR HYDRONIC HEA TING AND HOT W A TER SUPPL Y CAUTION TEXT PRINTED OR OUTLINED IN RED CONT AINS INFORMA TION RELA TIVE T O YOUR SAFETY . PLEASE READ THOROUGHL Y BEFORE INST ALLING AND USING THIS APPLIANCE. P ART NO. 21 1257-000 REV . 0 A DIVISION OF A. O. SMITH CORPORA TION EL P ASO, TX., MC BEE, SC., RE[...]

2 ROUGH-IN DIMENSIONS Figure 1. IMPORT ANT! Refer to "Installation Clearances" section of manual (page 7) for recommended service clearances prior to boiler placement. TOP VIEW LEFT SIDE T ABLE 2. ROUGH - IN DIMENSIONS AB CD E F Model Inches c m Inches c m Inches c m Inches c m Inches c m Inches c m GW/GB-1000 14.1 35.8 12.2 31.0 40.3 102[...]

3 TABLE 4: HEA T EXCHANGER PRESSURE DROP GB Models-Flow , Head Loss and T emperature Rise 20 Deg. F Rise 30 Deg. F Rise 40 Deg. F Rise Maximum Flow Rate Minimum Flow Rate GPM PD-FT GPM PD-FT G PM PD-FT GPM PD-FT Deg. F GP M PD-FT Deg. F MODEL Head Head Head Head Rise Head Rise GB - 1000 83.16 5.1 55.4 2.7 41.6 1.5 15 4 12.2 1 1 4 2 1 .5 4 0 GB - 13[...]

4 PRECAUTIONS IF THE UNIT IS EXPOSED TO THE FOLLOWING, DO NOT OPERA TE UNTIL ALL CORRECTIVE STEPS HA VE BEEN MADE BY A QUALIFIED SERVICEMAN: 1. EXPOSURE TO FIRE. 2. IF DAMAGED. 3. FIRING WITHOUT W A TER. 4. SOOTING . IF THE BOILER HAS BEEN EXPOSED TO FLOODING , IT MUST BE REPLACED. LIQUID PETROLEUM MODELS Boilers for propane or liquefied petroleum [...]

5 Example: A Genesis boiler is rated at 1,300,000 Btu/hr . input at sea level. At an altitude of 5,000 (1500m), the prejet orifices will decrease the input rate by 20% (= 4% x 5) to a new rating of 1,040,000 Btu/hr . (= 80% x 1,300,000 Btu/hr .) The input reduction is achieved by the prejet orifices through self-regulation. FEA TURES/CONTROLS MUL T[...]

6 probe is not supplied with the GB models. A tank probe can be used as an option to control loop temperature and unit staging. Additionally , the Inlet T emperature Probe can be used as the loop thermostat in some heating (GB) applications. These types of controls connect to designated wires in the junction box at the rear of the boiler . Do not o[...]

7 • THE BOILER MUST NOT BE INST ALLED ON CARPETING . • THE BOILER SHOULD NOT BE LOCA TED IN AN AREA WHERE IT WILL BE SUBJECT TO FREEZING. • THE BOILER SHOULD BE LOCA TED NEAR A FLOOR DRAIN. • THE BOILER SHOULD BE LOCA TED IN AN AREA WHERE LEAKAGE FROM THE BOILER OR CONNECTIONS WILL NOT RESUL T IN DAMAGE T O THE ADJACENT AREA OR T O LOWER FL[...]

8 PROVIDED FOR PROPER COMBUSTION AND VENTILA TION IN ACCORDANCE WITH THE NA TIONAL FUEL GAS CODE , ANSI Z223.1 OR CAN/CSA-B149.1 AND .2 (LA TEST EDITIONS) OR APPLICABLE PROVISIONS OF THE LOCAL BUILDING CODES. AN INSUFFICIENT SUPPL Y OF AIR MA Y RESUL T IN A YELLOW , LUMINOUS BURNER FLAME, CARBONING OR SOOTING OF THE FINNED HEA T EXCHANGER, OR CREA [...]

9 1. Seal any unused opening in the common venting system. 2. Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion or other unsafe condition. 3 . Isolate the space containing the appliance(s) remaining connected to the common venting system as much as possible[...]

10 ST ANDARD VENT - VERTICAL (CA TEGORY I) IMPORT ANT! VENT PRESSURE MUST BE MAINT AINED BETWEEN -0.02" W .C. AND -0.04" W .C. A T 24" (61.0 cm) ABOVE BOILER COLLAR. • 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 determine[...]

11 T ABLE 8. ST ANDARD HORIZONT AL VENTING (CA TEGOR Y III) ST ANDARD VENT - HORIZONT AL (CA TEGOR Y III) W ARNING: No substitutions of flue pipe or vent cap material are allowed. Such substitutions would jeop ardize the safety and health of inhabitants. • A maximum of two elbows can be used on inlet and outlet vent piping respectively . Each elb[...]

12 DIRECT VENT - VERTICAL (CA TEGOR Y I) T ABLE 9. DIRECT VENT (VERTICAL EXHAUST CONFIGURA TIONS) • Connection for the appliance exhaust vent to the stack must be as direct as possible. Maximum and minimum venting length for Category I appliances shall be determined per the latest edition of the National Fuel Code (U.S.) and CAN/CSA-B149.1 and .2[...]

13 DIRECT VENT - HORIZONT AL (CA TEGOR Y III) W ARNING: No substitutions of flue pipe or vent cap material are allowed. Such substitutions would jeop ardize 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 [...]

14 ST ANDARD (VERTICAL) VENTING , CA TEGORY I THIS BOILER MA Y BE VENTED ACCORDING T O T ABLE 7 (ALSO SEE FIGURE 5). A T LEAST TYPE B VENTING MUST BE USED WITH THE ST ANDARD VENTING OPTION (thru-the-roof) USING THE NA TIONAL FUEL GAS CODE VENT T ABLES.* TYPE B VENT PIPE CANNOT BE USED IF THE BOILER IS VENTED HORIZONT ALL Y OR AS A DIRECT VENT (SEE [...]

15 CONVENTIONAL SP ACE HEA TING INST ALLA TION Modern fin type boilers are exceptionally fast heating units. The low water volumes in relation to firing rates require special attention to water flow rates for smooth, efficient operation. These considerations for the A. O. Smith copper heat exchanger boilers are covered below . Refer to table 4 show[...]

16 Figure 10. Single or Multiple Boiler Installation Diagram The circuits should be spaced on the header at a minimum of 3" (7.6 cm) center to center . Install a balancing cock in each return line. Manifold headers are recommended for split systems with or without zone valves and also those installations with zone circulators. If the system is[...]

17 mandatory but offers smooth, efficient operation of a modern system. Normal use of flow control valves is required to prevent cross circulation of zones as with any multiple pump system. Large systems with multiple boilers should include main water temperature controls (with or without outdoor reset) to sequence the boiler on and off, in relatio[...]

18 ONE GENESIS (MODEL GW) HOT W A TER SUPPL Y BOILER WITH HORIZONT AL T ANK Figure 12. T ank probe inst allation. PRESSURE RELIEF V AL VE RA TING SHOULD NOT EXCEED PRESSURE CAP ACITY OF ANY COMPONENT IN THE SYSTEM. PIPING SHOULD CONFORM TO LOCAL CODES. BALL V AL VES ARE SHOWN FOR SERVICING BOILER. HOWEVER, LOCAL CODES SHALL GOVERN THEIR USAGE. DANG[...]

19 ONE GENESIS (MODEL GW) HOT W A TER SUPPL Y BOILER WITH VERTICAL T ANK Figure 13. Single boiler with vertical tank. PRESSURE RELIEF V AL VE RA TING SHOULD NOT EXCEED PRESSURE CAP ACITY OF ANY COMPONENT IN THE SYSTEM. PIPING SHOULD CONFORM TO LOCAL CODES. BALL V AL VES ARE SHOWN FOR SERVICING BOILER. HOWEVER, LOCAL CODES SHALL GOVERN THEIR USAGE. [...]

20 T able 13. Suggested Pipe Size For Multiple Gas Appliances (Natural) T able 14. Suggested Pipe Size For Multiple Gas Appliances (Prop ane Gas) Length of Pipe in Feet (Metres) Maximum Capacity of Pipe in BTU/hr and kW for Gas Pressures of 14 in. W .C. (0.5 psi) or Less and a Pressure Drop of 0.5 in. W .C . (based on 0.60 Specific Gravity Gas w/He[...]

21 GAS CONNECTIONS W ARNING THIS BOILER IS NOT INTENDED T O OPERA TE A T GAS SUPPL Y PRESSURE OTHER THAN SHOWN ON THE RA TING PLA TE. EXPOSURE T O HIGHER GAS SUPPL Y PRESSURE MA Y CAUSE DAMAGE T O GAS V AL VES WHICH CAN RESUL T IN FIRE OR EXPLOSION. IF OVERPRESSURE HAS OCCURRED SUCH AS THROUGH IMPROPER TESTING OF GAS LINES OR EMERGENCY MALFUNCTION [...]

22 WIRING CONNECTIONS ALL ELECTRICAL WORK MUST BE INST ALLED IN ACCORDANCE WITH THE MOST RECENT VERSION OF THE NA TIONAL ELECTRICAL CODE/CANADIAN ELECTRICAL CODE AND MUST CONFORM TO LOCAL REGULA TIONS. AN ELECTRICAL GROUND IS REQUIRED TO REDUCE RISK OF ELECTRIC SHOCK OR POSSIBLE ELECTROCUTION. Make the ground connection to the wire provided in the [...]

23 PURGING OF GAS LINE Gas line purging is required with new piping or systems in which air has entered. CAUTION PURGING SHOULD BE PERFORMED BY PERSONS EXPERIENCED IN THIS TYPE OF GAS SER VICE TO A VOID RISK OF FIRE OR EXPLOSION. PURGE DISCHARGE MUST NOT ENTER CONFINED AREAS OR SP ACES WHERE IGNITION CAN OCCUR. THE AREA MUST BE WELL VENTILA TED AND[...]

24 Lighting Instructions for the G(B/W) 1000 through 2500 models A . THIS APPLIANCE DOES NOT HA VE A PILOT . IT IS EQUIPPED WITH AN IGNITION DEVICE WHICH AUTOMA TICALL Y LIGHTS THE BURNER. DO NOT TR Y TO LIGHT THE BURNER BY HAND. B . BEFORE LIGHTING: SMELL ALL AROUND THE APPLIANCE AREA FOR GAS. BE SURE TO SMELL NEXT TO THE FLOOR BECAUSE SOME GAS IS[...]

25 Lighting Instructions for the G(B/W) 1000 through 2500 models FOR YOUR SAFETY READ BEFORE OPERA TING OPERA TING INSTRUCTIONS TO TURN OFF GAS TO APPLIANCE W ARNING: IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTL Y , A FIRE OR EXPLOSION MA Y RESUL T CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE. A . THIS APPLIANCE DOES NOT HA VE A PILOT[...]

26 CONTROL SYSTEM DESCRIPTION OF MUL TI-ST AGE FIRING SYSTEM The Central Control Board (CCB) is responsible for staging the Ignition Control Boards (ICB) and monitoring safety limit devices, control of circulation pump, power vent, alarm output and IRI gas valves (only on IRI models). The thermostat also resides on the CCB with inputs available for[...]

27 switch "D" on the Central Control Board is placed in the "ON" position, it will show the temperature at the tank probe. (See Figure 14.) The push buttons on the Display Board allow the user to program and view several system parameters described in the following text. The Display Board is connected to the Central Control Boar[...]

28 Figure 16. Display Board High Gas Fail: Gas Pressure at Manifold too High L WCO: Low water Cutoff activated. Not enough water . Power V ent Fail: Not Enough Air to Close Switch Stage One: Failure on Stage One S tage T wo: Failure on S tage T wo Stage Three: Failure on Stage Three Stage Four: Failure on Stage Four Y ellow Parameter Set Light s Th[...]

29 1. Press the SELECT push-button on the display board until both the Set-Pt LED and Inlet W ater T emperature LED (see Figure 16) are illuminated. 2. The LED display will show the current set-point temperature. 3 . Press and hold the ADJUST push-button. The displayed temperature will either increase or decrease. T o alternate between increasing o[...]

30 Procedure for Setting Pump Delay The Controller is factory set with a 45 second post circulate function. With the Display Board, the user has the capability to choose between a 45, 90, or 180 second post circulate time period, or turn the pump on continuously . This provides flexibility in selecting the post circulate time to meet specific insta[...]

31 drop out first followed by stages three, two and one. T o achieve maximum efficiency , stages will reignite if the system water temperature drops below the stage Set Point minus the Set Point Differential. Note: Once a stage is satisfied, the blower associated with that stage will allow a 25 second postpurge before it deactivates. 1 1. Once all [...]

32 with this boiler should receive periodic (every six months) inspection to assure proper operation. A low water cutoff device of the float type should be flushed every six months. Periodic checks, at least twice a year , should be made for water and/or gas leaks. More frequent inspections may be necessary depending on water conditions. The boiler[...]

33 CAUTION IF HEA T EXCHANGER MAINTENANCE REQUIRES TUBING REPLACEMENT , SPECIAL PROVISIONS SHALL BE T AKEN TO ENSURE THA T THE DAMAGED TUBES ARE CAREFULL Y REMOVED. REPLACEMENT TUBES MUST BE PROPERL Y INST ALLED AND EXP ANDED INTO THE ROLLED TUBE TUB. OVER-ROLLING, MISALIGNMENT OF TUBES OR IMPROPER TIGHTENING OF THE ASSEMBL Y MA Y RESUL T IN LEAKS [...]

34 For additional information please refer to the User’s Manual supplied with the boiler or contact: A.O. Smith T echnical Services 7 a.m. to 7 p.m. Central Time at: 1-800-527-1953 Our Internet Site is another source of information 24 hours a day . http://www .hotwater .com T able 19. Error Code Chart GENESIS II CONTROL - F AUL T OPERA TION F AUL[...]

35 NEW BOILER LIMITED W ARRANTY A. O. Smith Corporation, the warrant or , extends the following LIMITED W ARRANTY 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 warranto r to be defective in material or workmanship, the warrantor , at his[...]

36 REPLACEMENT P ARTS 5621 W . 1 15TH STREET , ALSIP , IL 60803 Phone: 800-433-2545 Fax: 800-433-2515 w w w .hotwater .com E-Mail: part s@hotwater .com[...]