A.O. Smith 401, 400, 402, 403, 405, 404 instruction manual For Your Safety Read Before Operating

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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.

A.THIS APPLIANCE DOES NOT HAVE A PILOT. IT IS EQUIPPED WITH AN IGNITION DEVICE WHICH AUTOMATICALLY LIGHTS THE BURNER. DO NOT TRY TO LIGHT THE BURNER BY HAND.

B.BEFORE OPERATING: SMELLALL AROUND THE APPLI- ANCE AREA FOR GAS. BE SURE TO SMELL NEXT TO THE FLOOR BECAUSE SOME GAS IS HEAVIER THAN AIR AND WILL SETTLE ON THE FLOOR.

WHAT TO DO IF YOU SMELL GAS

DO NOT TRY TO LIGHT ANY APPLIANCE.

DO NOT TOUCH ANY ELECTRIC SWITCH; DO NOT USEANY 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.

C.USE ONLY YOUR HAND TO PUSH IN OR TURN THE GAS CONTROL KNOB. NEVER USE TOOLS. IF THE KNOB WILL NOT PUSH IN OR TURN BY HAND, DON’T TRY TO REPAIR IT. CALLA QUALIFIED SERVICE TECHNICIAN. FORCE OR ATTEMPTED REPAIR MAY RESULT IN A FIRE OR EXPLOSION.

D.DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN UNDER WATER. IMMEDIATELY CALL A QUALIFIED SERVICE TECHNICIAN TO INSPECT THE APPLIANCE AND TO REPLACE ANY PART OF THE CONTROL SYSTEM AND ANY GAS CONTROL WHICH HAS BEEN UNDER WATER.

E.DO NOT OPERATE APPLIANCE UNLESS UNIT IS FILLED WITH WATERAND WATER LINES ARE FULLY OPEN.

Note: Knob cannot be turned to "OFF" unless knob is pushed in slightly. Do NOT force.

OPERATING INSTRUCTIONS

1.STOP! READ THE SAFETY INFORMATION THE NEXT STEP ABOVE ON THIS LABEL.

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.

5.REMOVE CONTROLACCESS PANEL.

6.REFER TO DIAGRAMS ABOVE. TURN TOP KNOB OF GAS CONTROL CLOCKWISE TO “OFF” POSITION, (FIGURE A).

7.WAIT FIVE (5) MINUTES TO CLEAR OUTANYGAS. THEN SMELL FOR GAS, INCLUDING NEAR THE FLOOR.

IF YOU SMELL GAS,

STOP ! FOLLOW “B” IN THE SAFETY INFORMA TION ABOVE ON THIS LABEL. IF YOU DON’T

SMELL GAS, GO TO THE NEXT STEP.

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.

12.IF THEAPPLIANCE WILLNOT OPERATE, FOLLOW THE INSTRUCTIONS “TO TURN OFF GAS TO THE APPLIANCE” AND CALL YOUR SERVICE TECHNICIAN OR GAS SUPPLIER.

TO TURN OFF GAS TO APPLIANCE

1.SET THE SYSTEM CONTROLLER TO THE LOWEST SETTING.

2.TURN POWER SWITCH ON APPLIANCE TO “OFF” POSITION.

3.REMOVEACCESS PANELTO EXPOSE GAS CONTROL.

4.REFER TO DIAGRAMS ABOVE. TURN TOP KNOB OF GAS CONTROL CLOCKWISE (TO “OFF” POSITION, (FIGURE A).

5.REPLACE CONTROLACCESS PANEL.

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Contents Installation Operation Maintenance Limited Warranty Copper Boilers for Hydronic Heating HOT Water SupplyGAS and Electrical Requirement DIMENSIONS/CAPACITIES DataDimensional Data Dimensions Data for Outdoor Configuration Recovery Capacities ForewordFEATURES/CONTROLS Differential Pressure Switch Combustion AIR Blower Blocked Flue Pressure SwitchWater Flow Switch ON/OFF SwitchInstallation Instructions Safety Relief ValvesRequired Ability LocationInstallation Clearances Chemical Vapor CorrosionLevelling AIR RequirementsVenting Horizontal Vent Installation System Installation Installation AS Boiler ReplacementINTAKE/EXHAUST Installation Requirements GeneralStandard Vent Vertical Category Type B orEquivalent 16 40.6 cmStandard Vent Horizontal Category III StainlessSteel IIIDirect Vent Vertical Exhaust Configurations Direct Vent Vertical CategoryDirect Vent Horizontal Exhaust Configurations Direct Vent Horizontal CategoryStainless GAL. Steel Sealed Stainless GAL.STEELHydronic Installation VAC System Controller Optional Space Heating ApplicationsInternal Contaminants Tank Probe Installation Procedure GAS Connections Water Line ConnectionsHard Water Conditions Tank Probe OptionalSingle boiler with horizontal tank Single boiler with vertical tank Suggested Pipe Size For Multiple Gas Appliances Propane Gas Single Unit INSTALLATION, Suggested Pipe Size Wiring ConnectionsDistance 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 Operation Filling and Purging Water SystemPurging of GAS Line Inlet GAS PressureFor Your Safety Read Before Operating For Your Safety Read Before Operating Adjustments Risk of Scalds TemperatureSetting Degree Burns on Adult Skin Control SystemAir Pressure Sensors open condition indicates fault Gas Pressure Sensors open condition indicates faultWater Level Sensor open condition indicates fault CCB/FCB Indicator Lamps & FusesCCB Ten Position Dipswitch Central Control Section SW1 CCB-SW2FCB Eight-Position Dipswitch Operating SequenceTemperature Setpoints System Control Algorithm UIM Operating ProceduresStages 1 and 2 will turn on in sequence from 1 to UIM ScreensTemperature Screen Status Displayed True Condition InputMenu Screen System Status ScreenDescription of FCB control states Operating Differentialsetpoint Adjustment Procedure Operating Setpoint Adjustment ProcedureHigh Limit Differential Setpoint Adjustment Procedure Fault Displayed Description Redled Lockout Hard Main Burners Tank Probe Tank Remote probe shorted or open FlashingDeliming Replacement Parts Tubecleaningprocedure Mechanical Removal of DepositsNEW Boiler Limited Warranty Conditions and ExceptionsTennessee Waltz Parkway, Ashland City, TN Phone