A.O. Smith 402, 400 Installation Instructions, Safety Relief Valves, Required Ability, Location

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DRAIN VALVE (Not Supplied)

Additional drain valves must be obtained and installed on each boiler and tank for draining purposes.

SAFETY RELIEF VALVES

Your local code authority may have other specific relief valve requirements not covered below.

WARNING

THE PURPOSE OF A SAFETY RELIEF VALVE IS TO AVOID EXCESSIVE PRESSURE WHICH MAY CAUSE TANK EXPLOSION, SYSTEM OR BOILER DAMAGE.

TO AVOID WATER DAMAGE A DRAIN LINE MUST BE CONNECTED TOA SAFETY RELIEF VALVE FOR DIRECT DISCHARGE TOA SAFE LOCATION. A DRAIN LINE MUST NOT BE REDUCED FROM THE SIZE OF THE VALVE OUTLET AND IT MUST NOT CONTAIN ANY VALVES BETWEEN THE BOILER AND THE RELIEF VALVE OR THE RELIEF VALVE AND THE DRAIN EXIT. IN ADDITION, THERE SHOULD NOT BE ANY RESTRICTIONS IN A DRAIN LINE NOR SHOULD IT BE ROUTED THROUGH AREAS WHERE FREEZING CONDITIONS MIGHT OCCUR. DO NOT THREAD OR CAP THE DRAIN LINE EXIT. RESTRICTING OR BLOCKING A DRAIN LINE WILL DEFEAT THE PURPOSE OF THE RELIEF VALVE AND MAY CREATE AN UNSAFE CONDITION. INSTALL A DRAIN LINE WITH A DOWNWARD SLOPE SUCH THAT IT NATURALLY DRAINS ITSELF.

If any safety relief valve is replaced, the replacement valve must comply with the latest version of the ASME Boiler and Pressure Vessel Code, Section IV (HEATING BOILERS). Select a relief valve with a discharge rating NOT less than the boiler input, and a set pressure NOT exceeding the working pressure of any component in the system.

The storage tank temperature and pressure relief valve must comply with the applicable construction provisions of the Standard for Relief Valves for Hot Water Supply Systems, ANSI Z21.22-CSA-

4.4(current edition). The valve must be of the automatic reset type and not embody a single-use type fusible plug, cartridge or linkage.

FOR HOT WATER HEATING SYSTEMS, the boilers are shipped with a 50 psi pressure relief valve. This relief valve is factory installed on the water outlet header of the boiler.

FOR HOT WATER SUPPLY SYSTEMS, the boilers are shipped with a 125 psi pressure relief valve. This relief valve is factory installed on the water outlet header of the boiler. This ASME-rated valve has a discharge capacity that exceeds the maximum boiler input rating and a pressure rating that does not exceed the maximum working pressure shown on the boiler rating plate.

In addition, a CSA design-certified and ASME-rated temperature and pressure (T & P) relief valve must be installed on every water storage tank in the hot water supply system; see Figures 11 and 13.

The T & P relief valve should have a temperature rating of 210°F (99°C), a pressure rating NOT exceeding the lowest rated working pressure of any system component, and a discharge capacity exceeding the total input of the water boilers supplying water to the storage tank.

Locate the T & P relief valve (a) in the top of the tank, or (b) in the

side of the tank on a center line within the upper six (6) inches (15 cm) of the top of the tank. The tapping shall be threaded in accordance with the latest edition of the Standard for Pipe Threads, General Purpose (inch), ANSI/ASME B1.20.1. The location of, or intended location for, the T & P relief valve shall be readily accessible for servicing or replacement.

INSTALLATION INSTRUCTIONS

REQUIRED ABILITY

INSTALLATION OR SERVICE OF THIS BOILER REQUIRES ABILITY EQUIVALENT TO THAT OFALICENSED TRADESMAN IN THE FIELD INVOLVED. PLUMBING, AIR SUPPLY, VENTING, GAS SUPPLYAND ELECTRICAL WORK ARE REQUIRED.

LOCATION

When installing the boiler, consideration must be given to proper location. The location selected should be as close to the stack or chimney as practical with adequate air supply and as centralized with the piping system as possible. The location should also be such that the gas ignition system components are protected from water (dripping, spraying, etc.) during appliance operation and service (circulator replacement, control replacement, etc.)

THE BOILER MUST NOT BE INSTALLED ON CARPETING.

THE BOILER SHOULD NOT BE LOCATED IN AN AREA WHERE IT WILL BE SUBJECT TO FREEZING.

THE BOILER SHOULD BE LOCATED NEAR A FLOOR DRAIN.

THE BOILER SHOULD BE LOCATED IN AN AREA WHERE LEAKAGE FROM THE BOILER OR CONNECTIONS WILL NOT RESULT IN DAMAGE TO THE ADJACENT AREA OR TO LOWER FLOORS OF THE STRUCTURE.

WHEN SUCH LOCATIONS CANNOT BE AVOIDED, A SUITABLE DRAIN PAN SHOULD BE INSTALLED UNDER THE BOILER. Such pans should be fabricated with sides at least 2-1/2" (6.5 cm) deep, with length and width at least 2" (5.1 cm) greater than the dimensions of the boiler and must be piped to an adequate drain. The pan must not restrict combustion air flow.

WARNING

THERE IS A RISK IN USING FUEL BURNING APPLIANCES IN ROOMS OR AREAS WHERE GASOLINE, OTHER FLAMMABLE LIQUIDS OR ENGINE DRIVEN EQUIPMENT OR VEHICLES ARE STORED, OPERATED OR REPAIRED. FLAMMABLE VAPORS ARE HEAVY AND TRAVEL ALONG THE FLOOR AND MAY BE IGNITED BY THE IGNITER OR MAIN BURNER FLAMES CAUSING FIRE OR EXPLOSION. SOME LOCAL CODES PERMIT OPERATION OF GAS APPLIANCES IF INSTALLED 18 INCHES (46.0 CM) OR MORE ABOVE THE FLOOR. THIS MAY REDUCE THE RISK IF LOCATION IN SUCH AN AREA CANNOT BE AVOIDED.

FLAMMABLE ITEMS, PRESSURIZED CONTAINERS OR ANY OTHER POTENTIAL FIRE HAZARDOUS ARTICLES MUST NEVER BE PLACED ON OR ADJACENT TO THE BOILER.

OPEN CONTAINERS OF FLAMMABLE MATERIAL SHOULD NOT BE STORED OR USED IN THE SAME ROOM WITH THE BOILER. A hot water boiler installed above radiation level or as required by

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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 ON/OFF Switch Differential Pressure Switch Combustion AIR BlowerBlocked Flue Pressure Switch Water Flow SwitchLocation Installation InstructionsSafety Relief Valves Required AbilityAIR Requirements Installation ClearancesChemical Vapor Corrosion LevellingVenting Horizontal Vent Installation General System InstallationInstallation AS Boiler Replacement INTAKE/EXHAUST Installation Requirements16 40.6 cm Standard Vent Vertical CategoryType B or EquivalentIII Standard Vent Horizontal CategoryIII Stainless SteelDirect Vent Vertical Category Direct Vent Vertical Exhaust ConfigurationsStainless GAL.STEEL Direct Vent Horizontal Exhaust ConfigurationsDirect Vent Horizontal Category Stainless GAL. Steel SealedHydronic Installation Internal Contaminants Space Heating ApplicationsVAC System Controller Optional Tank Probe Optional Tank Probe Installation ProcedureGAS Connections Water Line Connections Hard Water ConditionsSingle boiler with horizontal tank Single boiler with vertical tank Suggested Pipe Size For Multiple Gas Appliances Propane Gas BTU/HR Single Unit INSTALLATION, Suggested Pipe SizeWiring Connections Distance from Meter BTU InputGAS 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 Inlet GAS Pressure OperationFilling and Purging Water System Purging of GAS LineFor Your Safety Read Before Operating For Your Safety Read Before Operating Control System AdjustmentsRisk of Scalds Temperature Setting Degree Burns on Adult SkinCCB/FCB Indicator Lamps & Fuses Air Pressure Sensors open condition indicates faultGas Pressure Sensors open condition indicates fault Water Level Sensor open condition indicates faultCCB-SW2 CCB Ten Position Dipswitch Central Control Section SW1Operating Sequence FCB Eight-Position DipswitchUIM Screens Temperature Setpoints System Control AlgorithmUIM Operating Procedures Stages 1 and 2 will turn on in sequence from 1 toSystem Status Screen Temperature ScreenStatus Displayed True Condition Input Menu 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