A.O. Smith 404 manual

1 PRINTED IN U.S.A. 0906 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 TO YOUR SAFETY . PLEASE READ THOROUGHL Y BEFORE INST ALLING AND USING THIS APPLIANCE. 21251 1-000 MC BEE, SC., RENTON, W A., STRA TFORD-ONT ARIO, VELDHOVEN-THE NETHERLANDS, NANJING , CHINA w [...]

2 DIMENSIONS/CAP ACITIES DA T A 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. DIMENSIONAL DA T A 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 4[...]

3 DIMENSIONS DA T A FOR OUTDOOR CONFIGURA TION Figure 2. T ABLE 3. DIMENSIONAL DA T A AB C D E F G H J Model Inches cm Inches cm Inches cm Inches cm Inches cm Inches cm Inches cm Inches cm Inches c m GBO/GWO-1000 14 35.5 31.6 80.3 71.8 182.4 15.5 39.4 39.75 101 58.25 148 15.9 40.83 16 40.64 46.8 1 18.9 GBO/GWO -1300 24.75 62.9 31.6 80.3 82 208.3 15[...]

4 TABLE 5: PUMPING PERFORMANCE GUIDE TABLE 4: RECOVER Y CAP ACITIES TEMPERA TURE RISE - DEGREES °F (°C) Input Rating Water 40°F 50°F 60°F 70°F 80°F 90°F 100°F 1 10°F 120°F 130°F MODEL BTU/Hr . (kW) Flow (22.2°) (27.7°) (33.3°) (38.8°) (44.4°) (50°) (55.5°) (61.1°) (66.7°) (72.2°) GW - 1000 990,000 (290.1) G P H 2520 2016 1680 [...]

5 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 EXPER[...]

6 DIFFERENTIAL PRESSURE SWITCH The differential pressure switch ensures that a suf ficient differential exists between the air pressure in the pre-mix chamber and the inlet of the burner for safe, combustion and proper low NO x emission. The switch has two pressure tap s marked "+" (positive) and "-" (negative). Silicone tubing [...]

7 DRAIN V AL VE (Not Supplied) Additional drain valves must be obtained and inst alled on each boiler and tank for draining purposes. SAFETY RELIEF V AL VES Y our local code authority may have other specific relief valve requirements not covered below . W ARNING THE PURPOSE OF A SAFETY RELIEF V AL VE IS TO A VOID EXCESSIVE PRESSURE WHICH MA Y CAUSE[...]

8 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. W ARNING UNDER NO CIRCUMST ANCES SHOULD THE EQUIPMENT ROOM WHERE THE BOILER IS INST ALLED EVER BE UNDER NEGA TIVE PRESSURE. P ARTICULAR CARE MUST BE T AKEN WHEN EXHAUST F ANS, COMPRESSORS, AIR HA[...]

9 SEE FIGURE 6). 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 P AGES 12 THROUGH 15). ALL LOCAL UTILITY , ST A TE/ PROVINCIAL, REGULA TIONS ON VENTING MUST BE FOLLO[...]

10 POWER VENT (OPTIONAL) The length of vent used in horizontally vented installations can be extended beyond the lengths shown in T ables 1 1 and 13 by implementing the kits listed below: TABLE 9: POWER VENT KITS. CONNECTING BOILER TO A COMMON VENT Do not connect the boiler to a common vent or chimney with solid fuel burning equipment. This practic[...]

11 Figure 5. V ent T ermination Installation Clearances CAUTION DIRECT VENTING INTO DEAD AIR SP ACES SUCH AS ALLEYS, ATRIUMS AND INSIDE CORNERS CAN CAUSE RECIRCULA TION OF FLUE GASES. RECIRCULA TION OF FLUE GASES WILL CAUSE SOOTING , PREMA TURE F AILURE OF THE HEA T EXCHANGER AND ICING OF THE COMBUSTION AIR INT AKE DURING SEVERE COLD WEA THER. TO P[...]

12 ST ANDARD VENT - VERTICAL (CA TEGOR Y 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 determin[...]

13 T ABLE 1 1. 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 jeopardize the safety and health of inhabitants. • A maximum of two elbows can be used on inlet and outlet vent piping respectively . Each el[...]

14 DIRECT VENT - VERTICAL (CA TEGOR Y I) T ABLE 12. 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 Insta[...]

15 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 [...]

16 HYDRONIC INST ALLA TION The following is a brief description of the equipment required for installations noted in Figure 10. All installations must comply with local codes. T ABLE 14: INST ALLA TION ITEMS NO . SUGGESTED ITEMS FOR INST ALLA TION 1. P AIR OF SHORT PIPE NIPPLES, P AIR OF BOILER LOOP TEES AND BALL V AL VE BETWEEN SYSTEM SUPPL Y AND [...]

17 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. 24 V AC System Controller (Optional) GB models require a field supplied 24V AC operating control to be installed in the system such as: loop thermost at, indo[...]

18 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 . Before operating the boiler , the entire system must be filled with water , purged of air and checked for leaks. Do not use S top Leak or other boiler compounds. THE W A TER HEA TER S[...]

19 ONE GENESIS (MODEL GW) HOT W A TER SUPPL Y BOILER WITH HORIZONT AL T ANK Figure 12. T ank probe installation. 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. DANGE[...]

20 ONE GENESIS (MODEL GW) HOT W A TER SUPPL Y BOILER WITH VERTICAL T ANK Figure 13. Single boiler with vertical t ank. 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 SER VICING BOILER. HOWEVER, LOCAL CODES SHALL GOVERN THEIR USAGE[...]

21 T ABLE 15. Suggested Pipe Size For Multiple Gas Appliances (Natural) T ABLE 16. 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[...]

22 Where it is necessary to use more than the average number of pipe fittings i.e. elbows, tees, and valves in gas supply line, use a pipe larger than specified to compensate for increased pressure drop. Gas control trains are unique for each Genesis II unit. S tages one, two and three run sequentially left to right on the smaller units (GB/ GW 100[...]

23 GB/GW 2100 GB/GW 2500 GB/GW 1000 - 1500 GAS MANIFOLD ASSEMBL Y GB/GW 1850 Figure 14. GB/GW 1000 - 2500 Gas Manifold Assembly Diagrams.[...]

24 GENESIS GB/GW 1000-2500 SERIES 400 WIRING DIAGRAM FIGURE 15.[...]

25[...]

26 GENESIS GB/GW 1000-2500 SERIES 400 SCHEMA TIC DIAGRAM FIGURE 16.[...]

27[...]

28 Figure 17. CCB CENTRAL CONTROL BOARD[...]

29 Figure 18. FCB FLAME CONTROL BOARD Diagram[...]

30 Figure 19. PDB POWER DISTRIBUTION BOARD Diagram[...]

31 Fuse Protection The 24V AC 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 dam[...]

32 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 OPERA TING: SMELL ALL AROUND THE APPLI- ANCE AREA FOR GAS. BE SURE TO SMELL NEXT TO THE FLOOR BECAUSE SOME GA[...]

33 Lighting Instructions for the G(B/W) 1000 through 2500 models FOR YOUR SAFETY READ BEFORE OPERA TING OPERA TING INSTRUCTIONS T O 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 PILO[...]

34 T ABLE 20. RISK OF SCALDS. TEMPERA TURE TIME TO PRODUCE 2nd & 3rd SETTING DEGREE BURNS ON ADUL T SKIN OVER 170°F (77°C) NEARL Y INST ANT ANEOUS 160°F (71°C) ABOUT 1/2 SECOND 150°F (66°C) ABOUT 1-1/2 SECONDS 140°F (60°C) LESS THAN 5 SECONDS 130°F (54°C) ABOUT 30 SECONDS 120°F (49°C) OR LESS MORE THAN 5 MINUTES USE ANTI-SCALD V AL [...]

35 required): The CCB accepts analog temperature input s from up to three sensors (inlet, outlet and tank). • ECO input (CCB - required): 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 tripp[...]

36 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 . T[...]

37 Operating Sequence NOTE: The following sequence is based on a three-stage system. 1. The EMC 5000 controller has four modes of operation: Initialization, S tandby , Running, and Service. The internal CCB and FCB micros control these modes through a sequence of steps (or S tates) which are further described in the "UIM Operating Procedures&q[...]

38 followed by 15-second inter-purge period, then the system returns to step 7, if the "T rial 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. 10. If a flame is detected, stage two will be activated and start its [...]

39 • Menu Screen: Displayed when the user presses the "Menu" key . This screen is the selection point for the other 9 screens. • T emperature Screen: Displays the sensed temperatures of the Outlet, Inlet, and T ank probes. Also displayed is the calculated Delta T (Outlet minus Inlet) for the system. Shorted ("Short") and dis[...]

40 • Soft Fault S t ate: (See "Fault Description" section for list of soft and Auto Reset faults.) The CCB turns off the Powered V ent 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[...]

41 6. Use the UP or DOWN key to select the value you wish to enter . 7. T ouch the SELECT key to accept and store the new value. • Operating Dif ferential Setpoints: Each of the two stages has an independent Operating Differential setpoint. OPERA TING DIFFERENTIAL SETPOINT ADJUSTMENT PROCEDURE Each of the two stages has an independent Operating D[...]

42 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. 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[...]

43 “Low 24V AC” V olt age from transformer less than 18 vac Continuous Auto Reset Check transformer output. Should be over 24vac. May be caused by excessive current drain or a faulty transformer “Brown Out Reset” Indicates a brown out reset occurred - - - - None Caused by a momentary dip in voltage on the CCB +5vdc power bus. Cont act facto[...]

44 PREVENT A TIVE MAINTENANCE 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. Visually check flame characteristics through the view port located under the left-hand header on the boiler . Figure 22 shows the [...]

45 After placing the boiler in operation, check the ignition system safety shut-off devices for proper operation. T o 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 an[...]

46 all of the hardness (lime). For this reason it is recommended that a regular schedule for deliming be maintained. The time between cleaning will vary from two to six months depending upon water conditions and usage. A change of approximately 5 o F (3°C) in the normal temperature rise through the boiler is usually an indication that scale should[...]

47 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[...]

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