Instruction manual

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PRINTED 0809 212130-002

COPPER BOILERS

FOR HYDRONIC HEATING

AND HOT WATER SUPPLY

CAUTION

TEXT PRINTED OR OUTLINED IN RED CONTAINS

INFORMATION RELATIVE TO YOUR SAFETY. PLEASE

READ THOROUGHLY BEFORE INSTALLING AND USING

THIS APPLIANCE.

PLACE THESE INSTRUCTIONS ADJACENT TO BOILER AND

NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.

GB/GW-300, 400, 500, 650, 750

SERIES 400, 401, 402, 403, 404, 405

2-STAGE UNITS

for buying this

cost efficient, high recovery unit

from A. O. Smith Water Products Company

Please read through this informative manual and

pay special attention to the following:

ROUGH-IN DIMENSIONS/CAPACITIES PAGES 2 - 4

"FOREWORD" ON PAGE 5

"FEATURES" ON PAGES 6 - 7

"VENTING" ON PAGES 8 - 12

"GAS CONNECTIONS" 11 - 13

"INSTALLATION INSTRUCTIONS" ON PAGES 5 - 13

"WIRING DIAGRAM/SCHEMATIC" ON PAGES 14 - 15

"LIGHTING AND OPERATING" ON PAGES 19 - 20

"EMC5000 INSTRUCTIONS" ON PAGES 20 - 27

"SYSTEM EQUIPMENT INSTALLATION" PAGES 29 - 33

"TROUBLE SHOOTING" ON PAGES 27 - 28

"GENERAL MAINTENANCE" ON PAGES 34 - 35

"START-UP INSTRUCTIONS" ON PAGES 37 - 38

"LIMITED WARRANTY" ON PAGE 39

Instruction Manual

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:

• 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.

• Installation

• Operation

• Maintenance

• Limited Warranty

A DIVISION OF A. O. SMITH CORPORATION

MC BEE, SC., RENTON, WA.,

STRATFORD-ONTARIO, VELDHOVEN-THE NETHERLANDS

www.hotwater.com

Summary of content (44 pages)

PAGE 1
COPPER BOILERS FOR HYDRONIC HEATING AND HOT WATER SUPPLY • • • • Instruction Manual GB/GW-300, 400, 500, 650, 750 SERIES 400, 401, 402, 403, 404, 405 Installation Operation Maintenance Limited Warranty 2-STAGE UNITS Tha u o Y nk for buying this cost efficient, high recovery unit from A. O.
PAGE 2
FIGURE 2. FRONT FIGURE 1. LEFT SIDE FIGURE 3. TOP TABLE 1A. BASIC GAS AND ELECTRICAL PARAMETERS MODEL GB/GW 300 400 500 650 750 300 400 500 650 750 TYPE OF GAS Natural Natural Natural Natural Natural Propane Propane Propane Propane Propane VOLTS/HZ 120/60 120/60 120/60 120/60 120/60 120/60 120/60 120/60 120/60 120/60 MANIFOLD MANIFOLD PRESS. PRESS. AMPS Inches W.C. kPa 20 3.5 0.87 20 3.5 0.87 20 3.5 0.87 20 3.5 0.87 20 3.5 0.87 20 10.0 2.49 20 10.0 2.49 20 10.0 2.49 20 10.0 2.49 20 10.0 2.
PAGE 3
FIGURE 5. REAR FIGURE 6. TOP FIGURE 7. LEFT SIDE FIGURE 8. FRONT TABLE 1C. OUTDOOR UNIT DIMENSIONS MODEL NUMBER A B C D E F G1 G2 GBO/GWO-300 3 9 3/4 49 13 5/8 34 5/8 67.88 24 3/16 — GBO/GWO-400 3 9 3/4 55 1/4 13 5/8 34 5/8 68.88 24 3/16 — GBO/GWO-500 3 9 3/4 61 1/2 13 5/8 34 5/8 68.88 24 3/16 — GBO/GWO-650 3 9 3/4 70 7/8 13 5/8 34 5/8 68.63 — 27 11/16 GBO/GWO-750 3 9 3/4 77 1/8 13 5/8 34 5/8 68.
PAGE 4
TABLE 2. PUMP PERFORMANCE Model GW-300 GW-400 GW-500 GW-650 GW-750 Water Category Flow Rate GPM LPM Normal Hard Normal Hard Normal Hard Normal Hard Normal Hard 17 25 23 34 28 42 37 55 42 63 64 95 87 129 106 159 140 208 159 238 Head Loss Feet Meter Rise Temp. F C 4.4 9.5 8.0 6.0 4.6 9.1 6.2 12.2 9.7 18.8 30 20 30 20 30 20 30 20 30 20 1.3 2.9 2.4 1.8 1.4 2.8 1.9 3.7 3.0 5.7 2.4 5.3 4.4 3.3 2.6 5.1 3.4 6.8 5.4 10.
PAGE 5
FOREWORD CAUTION Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation of the boiler. CAUTION TEXT PRINTED OR OUTLINED IN RED CONTAINS INFORMATION RELATIVE TO YOUR SAFETY. PLEASE READ COMPLETELY BEFORE USING APPLIANCE. "Verify proper operation after servicing." Detailed installation diagrams are in this manual. These diagrams will provide the installer with a reference of materials needed and a suggested method of piping.
PAGE 6
FEATURES The T & P relief valve should have a temperature rating of 210°F, 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. IMPORTANT Only qualified personnel shall perform the initial firing of the heater. At this time the user should not hesitate to ask the start-up technician any questions regarding the operation and maintenance of the unit.
PAGE 7
If the boiler is installed above the level of heating system terminal units, a low water cutoff device must be installed in the boiler outlet at the time of installation. continuous operation). GB models require a field supplied operating control be installed in the system. Such as: loop stat, indoor/outdoor reset control, sequencing panel, or energy management system. These types of controls connect to the thermostat wires in the junction box on the boiler.
PAGE 8
UNCONFINED SPACE VENTING THE BOILER ! This boiler is approved to be vented as a Category I, Category III (horizontal venting), or a Direct Vent appliance. The Horizontal and Direct Venting options require a special vent kit. In buildings of conventional frame, brick or stone construction, unconfined spaces may provide adequate air for combustion.
PAGE 9
All boiler venting systems shall be installed in accordance with the National Fuel Gas Code, ANSI Z223.1 or CAN/CSA-B149.1 (current edition), or applicable provisions of the local building codes. SINGLE PIPE HORIZONTAL VENTING Vent sizing, installation and termination shall be in accordance with the NATIONAL FUEL GAS CODE, ANSI Z223.1 OR CAN/CSAB149.1. If applicable, all local, utility, state/provincial regulations on venting must be followed. This boiler may be vented according to Table 5A and 5C.
PAGE 10
8. Select the point of wall penetration where the minimum 1/4" per foot of slope up can be maintained. 9. The through the wall termination kit is suitable for zero clearance to combustible materials. 10.The mid point of the exhaust and intake air termination elbows must be a minimum of 12 inches from the exterior wall. CAUTION Direct venting into dead air spaces such as alleys, atriums and inside corners can cause recirculation of flue gases.
PAGE 11
TABLE 5C. INTAKE/VENTING CONFIGURATIONS, CATEGORIES AND MATERIALS Source for Combustion Exhaust Venting Venting Category Air Supply Configuration Boiler Room Air (Using combustion air from within the building.) Direct Venting (Outside combustion air thru sealed pipe to boiler intake.
PAGE 12
FIGURE 18. VENT TERMINATIONS AND INSTALLATION CLEARANCES TABLE 6. SINGLE UNIT INSTALLATION, SUGGESTED PIPE SIZE Maximum Equivalent Pipe Length Natural Gas 1,000 BTU/FT3 0.60 Specific Gravity @ 0.5 In. W.C. Pressure Drop Propane Gas 2,500 BTU/FT3 1.53 Specific Gravity @ 0.60 In.W.C.
PAGE 13
TABLE 7. SUGGESTED PIPE SIZE FOR MULTIPLE GAS APPLIANCES Nominal Iron Pipe Size in Inches 1 1 1/4 1 1/2 2 2 1/2 3 4 Maximum Capacity of Pipe in Cubic Feet of Gas per Hour for Gas Pressures of 14 in. W.C. (0.5 psi) or Less and a Pressure Drop of 0.5 in W.C. based on a 0.
PAGE 14
FIGURE 19.
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PAGE 16
FIGURE 20.
PAGE 17
PAGE 18
FIGURE 21A.
PAGE 19
FIGURE 21B.
PAGE 20
FIGURE 21C.
PAGE 21
Lighting Instructions for the G(B/W) 300 through 750 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.
PAGE 22
There are five (5) electrical connections that must be made for the boiler to operate correctly. Should an unsafe condition occur, the control will shut down the burner and display a red fault light as well as indicate the cause of the fault on the display. The operating programs for the system are stored in permanent memory inside the micros. Userselectable operating parameters and a history of detected faults are stored in re-writable memory in the micros.
PAGE 23
IRI Gas Valve Sensor: • IRI Gas Valve (CCB - optional): Normally open switch that closes when the IRI Gas Valve is operating correctly. This input is enabled/disabled by a dipswitch on the CCB. • Flame Sensor: Flame (CCB - required). Returns a signal to the microprocessor if flame is detected in the burner. If the probe is missing or shorted, the flame will not be detected. This input is enabled/disabled by a dipswitch on the FCB. • Provides power to activate the gas valve.
PAGE 24
CCB - Three position Dipswitch (SW2): This dipswitch is similar to the FCB dipswitches described below, but with only three switches being used: the number of blower speeds (switch #3), Hi Gas option (switch #2) and a spare (switch #1). Only the blower speed selection and Hi Gas are required because FCB1 always has a blower, igniter, flame checking, and the address is always stage 1.
PAGE 25
UIM Screens: On all screens a double vertical bar appears on the right side of the display each time a key is touched to indicate that a key has been activated. On several screens an indicator ">" appears on the left side of the display to indicate the active line. The "Up/ Down" keys are used to move the indicator to the desired line and the "Select" key is pressed to select the line.
PAGE 26
The following status information is displayed from the Status Displayed ECO LW/CO Blk Flue Flow Low Gas Tstat Hi Limit Pump IRI Gas Pwr IRI Gas Pwr Vent Alarm Pwr Vent Pwr BlwHi Prv Blw Hi BlwLo Prv Blw Lo Ignt Cur Ignit Gas Relay Hi Gas Flame • • • System Status Screen: *(True Condition) Outlet temperature too high Water Level low Flue blocked Water flowing Gas pressure low Thermostat requesting heat Outlet temp exceeds High Limit setpoint Pump output activated IRI output relay activated IRI Gas Valve
PAGE 27
This time allows the blower relay to activate, the blower to come up to speed, and the response from the blower prover to be filtered. if the igniter has reached a minimum of 2.8 amps, the gas valve safety circuit is then activated. If in this amount of time, the igniter fails to reach a minimum amp draw of 2.8 amps, the unit will re-cycle up to 3 times before locking out on igniter hardware failure. If the igniter does reach the minimum required amp draw of 2.
PAGE 28
units from trying to respond to the same request from the PC or supervisory network device. 7. Touch the SELECT key to accept and store the new value. • High Limit Differential: The outlet temperature must be below the automatic High Limit setpoint minus the High Limit Differential setpoint before a call for heat can be generated.
PAGE 29
UIM LED's The three LED's to the right of the LCD indicate the status of the overall system. The red LED indicates that a fault has been detected and the system has stopped running. It is on continuously for soft faults and flashes for hard faults. The Yellow LED indicates that the boiler is in a ready mode waiting for a call for heat command. When on continuously the Green LED indicates that the system is in the heating mode.
PAGE 30
“Blower Prov Stg* Blower pressure is too low it they should have been closed. Check blower, switch contact, wiring, and for air leaks. “Blocked Flue” Flue is Blocked Continuous SOFT Caused by the blocked flue switch contacts being open when they should have been closed. Check for flue blockage,switch contacts, wiring. “High Limit” Outlet temp. exceeded high limit setpoint Continuous Auto Reset Caused when the temperature of the outlet probe exceeds the high limit setpoint.
PAGE 31
if units are to be used for heating potable water, the information describing specific systems is found starting on page 33. Installations must comply with all local codes. TEMPERATURE REGULATION DANGER HOT WATER TEMPERATURES REQUIRED FOR AUTOMATIC DISHWASHER AND LAUNDRY USE CAN CAUSE SCALD BURNS RESULTING IN SERIOUS PERSONAL INJURY AND/ OR DEATH. THE TEMPERATURE AT WHICH INJURY OCCURS VARIES WITH THE PERSON'S AGE AND TIME OF EXPOSURE.
PAGE 32
ONE GENESIS (MODEL GW) HOT WATER SUPPLY BOILER WITH HORIZONTAL TANK PRESSURE RELIEF VALVE RATING SHOULD NOT EXCEED PRESSURE CAPACITY OF ANY COMPONENT IN THE SYSTEM. PIPING SHOULD CONFORM TO LOCAL CODES. BALL VALVES ARE SHOWN FOR SERVICING BOILER. HOWEVER, LOCAL CODES SHALL GOVERN THEIR USAGE. IMPORTANT SAFETY FLOW SWITCH PROTECTS THE BOILER IN CASE OF WATER SERVICE INTERRUPTION OR CIRCULATOR FAILURE.
PAGE 33
ONE GENESIS (MODEL GW) HOT WATER SUPPLY BOILER WITH VERTICAL TANK PRESSURE RELIEF VALVE RATING SHOULD NOT EXCEED PRESSURE CAPACITY OF ANY COMPONENT IN THE SYSTEM. PIPING SHOULD CONFORM TO LOCAL CODES. BALL VALVES ARE SHOWN FOR SERVICING BOILER. HOWEVER, LOCAL CODES SHALL GOVERN THEIR USAGE. IMPORTANT SAFETY FLOW SWITCH PROTECTS THE BOILER IN CASE OF WATER SERVICE INTERRUPTION OR CIRCULATOR FAILURE.
PAGE 34
Primary/secondary pumping of both the chiller(s) and the boiler(s) is an excellent winter-summer change-over method, because cooling flow rates are much more than heating flow rates. In this way each system (heating or cooling) is circulated independently. SYSTEM INSTALLATION - Individual controls, or the separate stages of a step controller, should fire a boiler and also start the boiler loop circulating pump whenever that boiler is fired.
PAGE 35
Supply and return headers of the old system should be connected to the boiler loop with a pair of tees set close together. The boiler loop pump and the boiler(s) should be wired to operate only when any of the system pumps are in operation. The number of zone pumps that may be in operation at any particular time will take their required flow rate out from the first tee in the boiler piping. This water will be circulated through the proper branches from the supply header to the zones calling for heat.
PAGE 36
HARD WATER CONDITIONS 2. Where hard water conditions exist, water softening or the threshold type of water treatment is recommended. This will protect the dishwashers, coffee urns, water heaters, water piping and other equipment. When water softening or water treatment is not practical, a comparatively easy method of periodic lime removal from the unit must be employed. Vent all high points in system to purge system of air. Provisions should be made to permit manual venting of radiators or convectors.
PAGE 37
• System control (tank probe, thermostat, etc.) is calling for appliance operation (call for heat). lockout. Upon lockout, manually push the SELECT push-button on the UIM to restart the boiler. • Other contacts (switches) are closed (low water cutoff, flow switch, limit controls, pressure switches, etc.) ON/OFF SWITCH • Gas supply pressure is within the maximum and minimum operating ranges listed on the appliance rating plate/label. • Appliance is wired according to wiring diagram.
PAGE 38
HEAT EXCHANGER PREVENTIVE MAINTENANCE WARNING SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF, TURN OFF THE MANUAL GAS CONTROL VALVE TO THE APPLIANCE. In most water supply systems some solids exist. As the water is heated, these tend to drop out depositing as scale or lime. This scale must be removed before the heat exchanger tubes become blocked. COMBUSTION AIR FILTER CAUTION Lime accumulation can reduce the life of the equipment, reduce efficiency and waste fuel.
PAGE 39
Start-up Instructions COPPER BOILERS FOR HYDRONIC HEATING AND HOT WATER SUPPLY SERIES 400, 401,402, 403, 404, 405, 2-Stage Units Before starting the boiler please review the Boiler’s Instruction Manual (AOS Part Number 212130-002) supplied with the boiler. This is a powered combustion copper tube boiler. If you are not familiar with a powered combustion boiler please contact an authorized A.O. Smith representative before starting the unit. This boiler is equipped with an EMC5000 control system.
PAGE 40
Temperature Setpoints (Dual Stage Ignition) Before starting the boiler, refer to the "Operating Setpoint Adjustment Procedure" section in the boiler’s Instruction Manual. Starting the boiler for the first time. The boiler is tested at the factory and should start properly if installed in accordance with the Boiler’s Instruction Manual. The boiler may have a slight rumble on a cold start. This is normal and will not harm the unit nor is it a safety issue.
PAGE 41
NOTES 41
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NOTES 42
PAGE 43
NEW BOILER LIMITED WARRANTY A. O. Smith Corporation, the warrantor, extends the following LIMITED WARRANTY to the owner of this hot water boiler: 1. If within TEN years after initial installation of the boiler, the heat exchanger shall prove upon examination by the warrantor to be defective in material or workmanship, the warrantor, at his option, will exchange or repair such part or portion.
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A DIVISION OF A. O. SMITH CORPORATION MC BEE, SC., RENTON, WA., STRATFORD-ONTARIO, VELDHOVEN-THE NETHERLANDS www.hotwater.