A.O. Smith 402, 400, 401 instruction manual Installation Operation Maintenance Limited Warranty

Page 1

COPPER BOILERS FOR

HYDRONIC HEATING AND

HOT WATER SUPPLY

Installation

Operation

Maintenance

Limited Warranty

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

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

WHAT TO DO IF YOU SMELL GAS:

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.

PLACE THESE INSTRUCTIONS ADJACENT TO BOILER AND

NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.

Instruction Manual

GB/GW MODELS:

1000, 1300, 1500, 1850, 2100, 2500

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 THIS APPLIANCE.

for buying this cost efficient, high recovery unit from A. O. Smith Water Products Co.

You should thoroughly read and understand this manual before installation and/or operation of this boiler. Please pay particular attention to the important safety and operating instructions as well as the WARNINGS and CAUTIONS.

CONTENTS

PAGE

DIMENSIONS/CAPACITIES DATA

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

MC BEE, SC., RENTON, WA.,

STRATFORD-ONTARIO, VELDHOVEN-THE NETHERLANDS,

NANJING, CHINA

www.hotwater.com / email:parts@hotwater.com

PRINTED IN U.S.A. 0906

1

212511-000

 

 

 

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Contents Copper Boilers for Hydronic Heating HOT Water Supply Installation Operation Maintenance Limited WarrantyDimensional Data DIMENSIONS/CAPACITIES DataGAS and Electrical Requirement Dimensions Data for Outdoor Configuration Foreword Recovery CapacitiesFEATURES/CONTROLS Blocked Flue Pressure Switch Differential Pressure Switch Combustion AIR BlowerWater Flow Switch ON/OFF SwitchSafety Relief Valves Installation InstructionsRequired Ability LocationChemical Vapor Corrosion Installation ClearancesLevelling AIR RequirementsVenting Horizontal Vent Installation Installation AS Boiler Replacement System InstallationINTAKE/EXHAUST Installation Requirements GeneralType B or Standard Vent Vertical CategoryEquivalent 16 40.6 cmIII Stainless Standard Vent Horizontal CategorySteel IIIDirect Vent Vertical Category Direct Vent Vertical Exhaust ConfigurationsDirect Vent Horizontal Category Direct Vent Horizontal Exhaust ConfigurationsStainless GAL. Steel Sealed Stainless GAL.STEELHydronic Installation Internal Contaminants Space Heating ApplicationsVAC System Controller Optional GAS Connections Water Line Connections Tank Probe Installation ProcedureHard Water Conditions Tank Probe OptionalSingle boiler with horizontal tank Single boiler with vertical tank Suggested Pipe Size For Multiple Gas Appliances Propane Gas Wiring Connections Single Unit INSTALLATION, Suggested Pipe SizeDistance from Meter BTU Input BTU/HRGAS Manifold Assembly Genesis GB/GW 1000-2500 Series 400 Wiring Diagram Page Genesis GB/GW 1000-2500 Series 400 Schematic Diagram Page CCB Central Control Board FCB Flame Control Board Diagram PDB Power Distribution Board Diagram Filling and Purging Water System OperationPurging of GAS Line Inlet GAS PressureFor Your Safety Read Before Operating For Your Safety Read Before Operating Risk of Scalds Temperature AdjustmentsSetting Degree Burns on Adult Skin Control SystemGas Pressure Sensors open condition indicates fault Air Pressure Sensors open condition indicates faultWater Level Sensor open condition indicates fault CCB/FCB Indicator Lamps & FusesCCB-SW2 CCB Ten Position Dipswitch Central Control Section SW1Operating Sequence FCB Eight-Position DipswitchUIM Operating Procedures Temperature Setpoints System Control AlgorithmStages 1 and 2 will turn on in sequence from 1 to UIM ScreensStatus Displayed True Condition Input Temperature ScreenMenu Screen System Status ScreenDescription of FCB control states High Limit Differential Setpoint Adjustment Procedure Operating Setpoint Adjustment ProcedureOperating Differentialsetpoint Adjustment Procedure Fault Displayed Description Redled Lockout Hard Tank Probe Tank Remote probe shorted or open Flashing Main BurnersDeliming Tubecleaningprocedure Mechanical Removal of Deposits Replacement PartsConditions and Exceptions NEW Boiler Limited WarrantyTennessee Waltz Parkway, Ashland City, TN Phone