A.O. Smith 403, 400, 402, 401, 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: 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.

WHAT TO DO IF YOU SMELL GAS

DO NOT TRY TO LIGHT ANY APPLIANCE.

DO NOT TOUCH ANY ELECTRIC 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.

C.USE ONLYYOUR HAND TO TURN THE MAIN MANUAL GAS VALVE HANDLE. NEVER USE TOOLS. IF THE HANDLE WILL NOT TURN BY HAND, DON’T TRY TO REPAIR IT. CALL A QUALIFIEDSERVICETECHNICIAN.FORCEORATTEMPTED 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 REPLACEANY PART OF THE CONTROL SYSTEMAND ANY GAS CONTROL WHICH HAS BEEN UNDER WATER.

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

OPERATING INSTRUCTIONS

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

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 WHICH AUTOMATICALLY LIGHTS THE BURNER, DO NOT TRY TO LIGHT THE BURNER BY HAND.

6.WAIT FIVE (5) MINUTES TO CLEAR OUT ANY GAS. 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.

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 THE APPLIANCE WILL NOT OPERATE, FOLLOW THE INSTRUCTIONS “TO TURN OFF GAS TO THE APPLI- ANCE” 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.TURN MAIN MANUAL GAS VALVE TO “OFF” POSITION, (FIGURE “B”). THE VALVEIS “OFF” WHEN THE HANDLE IS PERPENDICULAR TO THE GAS FLOW DIRECTION.

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Contents Copper Boilers for Hydronic Heating HOT Water Supply Installation Operation Maintenance Limited WarrantyDIMENSIONS/CAPACITIES Data Dimensional 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 Space Heating Applications Internal ContaminantsVAC 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 Operating Setpoint Adjustment Procedure High Limit Differential 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