A.O. Smith 405, 400, 402 Single Unit INSTALLATION, Suggested Pipe Size, Wiring Connections, Btu/Hr

Gas Pipe sizing may be larger than heater connections on installations where a significant run of piping is required. To prevent damage, care must be taken not to apply too much torque when attaching gas supply pipe to gas inlet.

Fittings and unions in the gas line must be metal to metal type.

Apply joint compounds (pipe dope) sparingly and only to the male threads of pipe joints. Do not apply compound to the first two threads. Use compounds resistant to the action of liquefied petroleum gases.

1.CORRECT GAS - Make sure gas on which the boiler will operate is the same as that specified on the rating plate. Do not install the boiler if equipped with a different type of gas. Consult your gas supplier.

2A. SIZING GAS SUPPLY LINE (For single boiler installations). See Table 17.

2B. SIZING GAS SUPPLY LINE (For multiple installations of two or more boilers). See Tables 15 (Natural Gas) and 16 (Propane Gas).

TABLE 17. SINGLE UNIT INSTALLATION, SUGGESTED PIPE SIZE

DISTANCE FROM METER

BTU INPUT	0-50'	51-100'	101-200'	201-300'	301-500'
990,000	2"	2"	2 1/2"	2 1/2"	2 1/2"
1,300,000	2"	2 1/2"	2 1/2"	3"	3"
1,500,000	2"	2 1/2"	3"	3"	3 1/2"
1,850,000	2 1/2"	2 1/2"	3"	3"	3 1/2"
2,100,000	2 1/2"	3"	3"	3 1/2"	4"
2,500,000	2 1/2"	3"	4"	4"	4 1/2"

Use Tables 15 or 16, which are taken from ANSI booklet Z223.1, NATIONAL FUEL GAS CODE, or CAN/CSA-B149.1 (current edition) to size iron pipe or equivalent gas supply line.

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. Stages one, two and three run sequentially left to right on the smaller units (GB/ GW 1000 -1500) while stage one is located in different positions on the larger units. Gas manifold diagrams are depicted in Figure 14.

WIRING CONNECTIONS

ALL ELECTRICAL WORK MUST BE INSTALLED IN ACCORDANCE WITH THE NATIONAL ELECTRICAL CODE, ANSI/NFPA 70 OR CSA-C22.1 CURRENT EDITION AND MUST CONFORM TO LOCAL REGULATIONS.

AN ELECTRICAL GROUND IS REQUIRED TO REDUCE RISK OF ELECTRIC SHOCK OR POSSIBLE ELECTROCUTION. Make the ground connection to the wire provided in the electrical supply junction box on the boiler.

Grounding and all wiring connected to this boiler must conform to the local code authority having jurisdiction or, in the absence of such requirements, with the National Electrical Code, ANSI/NFPA 70 or CSA-C22.1 current edition.

The Central Control Board and Flame Control Boards that make up the control system are micro-processor based which make them vulnerable to voltage and amperage fluctuations in the power supply. Refer to Connection and Schematic Diagrams. See Figures 15 and 16.

IF ANY OF THE ORIGINAL WIRE, AS SUPPLIED WITH THE APPLIANCE, MUST BE REPLACED, IT MUST BE REPLACED WITH TYPE 105°C WIRE OR ITS EQUIVALENT.

The Genesis Hot Water Supply Boiler must be connected to a single phase dedicated and isolated line source:120volts, 60Hz,and30Amps.

TABLE 18. Orifice Size for Natural and Propane (LP) Gases (U.S. and Canada Installations, for high altitude up to 4,500 ft. (1,372 m).

				Drill Size
	Input Rating	Number of
Model	BTU/HR	Burners	Natural (4 Holes)	Propane (3 Holes)
G(B,W) 1000	990,000	10	0.111"	0.075"
G(B,W) 1300	1,300,000	13	0.111"	0.075"
G(B,W) 1500	1,500,000	15	0.111"	0.075"
G(B,W) 1850	1,850,000	19	0.111"	0.075"
G(B,W) 2100	2,100,000	21	0.111"	0.075"
G(B,W) 2500	2,490,000	25	0.111"	0.075"

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