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A.O. Smith 200 Instruction Manual

A. o. smith instruction manual copper boilers for hydronic heating and hot water supply 200 series, 201 series
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See also: Service Handbook , Installation
Enlarged version
COPPER BOILERS FOR
HYDRONIC HEATING AND
HOT WATER SUPPLY
• Installation
• Operation
• Maintenance
• Limited Warranty
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:
•
Extinguish any open flame.
•
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.
PLACE THESE INSTRUCTIONS ADJACENT TO BOILER AND
NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.
PRINTED IN U.S.A. 2526 0501
Instruction Manual
GB/GW
1000, 1300, 1500, 1850, 2100, 2500
SERIES 200, 201
TEXT PRINTED OR OUTLINED IN RED CONTAINS
INFORMATION RELATIVE TO YOUR SAFETY.
PLEASE READ THOROUGHLY BEFORE INSTALLING
AND USING THIS APPLIANCE.
for buying this cost
efficient, high recovery unit from
A. O. Smith Water Products Co.
You should thoroughly read and understand this
manual before installation and/or operation of this
boiler. Please pay particular attention to the
important safety and operating instructions as well
as the WARNINGS and CAUTIONS.
CONTENTS
ROUGH-IN DIMENSIONS/CAPACITIES ............. 2 - 3
FOREWORD ..................................................... 4 - 5
FEATURES/CONTROLS ................................... 5 - 6
INSTALLATION INSTRUCTIONS ................... 6 - 22
VENTING ....................................................... 8 - 14
SYSTEM INSTALLATION .............................. 15 - 19
HYDRONIC INSTALLATION .......................... 15 - 17
GAS CONNECTIONS .................................... 20 - 21
OPERATION ................................................ 22 - 23
LIGHTING AND OPERATING ......................... 24 - 25
CONTROL SYSTEM .................................... 26 - 31
PREVENTATIVE MAINTENANCE ................ 31 - 33
TROUBLE SHOOTING .................................. 33 - 34
LIMITED WARRANTY .......................................... 35
WIRING DIAGRAM/SCHEMATIC .................. 36 - 37
A DIVISION OF A. O. SMITH CORPORATION
EL PASO, TX., MC BEE, SC., RENTON, WA.,
STRATFORD-ONTARIO, VELDHOVEN-THE NETHERLANDS
www.hotwater.com
1
:
MODELS
CAUTION
PAGE
PART NO. 211257-000 REV. 0

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Summary of Contents for A.O. Smith 200

  • Page 1: Table Of Contents

    PRINTED IN U.S.A. 2526 0501 Instruction Manual GB/GW MODELS 1000, 1300, 1500, 1850, 2100, 2500 SERIES 200, 201 CAUTION TEXT PRINTED OR OUTLINED IN RED CONTAINS INFORMATION RELATIVE TO YOUR SAFETY. PLEASE READ THOROUGHLY BEFORE INSTALLING AND USING THIS APPLIANCE.

  • Page 2: Rough-In Dimensions/Capacities

    ROUGH-IN DIMENSIONS TOP VIEW FRONT VIEW TABLE 1: GAS AND ELECTRICAL CHARACTERISTICS Manifold Pressure Model Type of Gas Inches W.C. kPa GW/GB-1000 thru 2500 NATURAL GW/GB-1000 thru 2500 PROPANE All Models - Maximum Supply Pressure: 14.0 In. W.C. (3.49 kPa) Minimum Supply Pressure Natural Gas: 6.0 In.
  • Page 3 TABLE 3: RECOVERY CAPACITIES Input Rating MODEL BTU/Hr. (kW) GW - 1000 990,000 (290.1) GW - 1300 1,300,000 (380.9) GW - 1500 1,500,000 (439.5) GW - 1850 1,850,000 (542.0) GW - 2100 2,100,000 (615.3) GW - 2500 2,490,000 (729.6) TABLE 4: HEAT EXCHANGER PRESSURE DROP 20 Deg.

  • Page 4: Foreword

    FOREWORD These designs comply with the latest edition of the American National Standards for Gas-Fired, Low-Pressure Steam and Hot Water Boilers, ANSI Z21.13 and CGA 4.9/CGA 3.3 latest edition, as a low pressure boiler. Detailed installation diagrams are found in this manual. These diagrams will serve to provide the installer a reference for the materials and methods of piping necessary.

  • Page 5: Control System

    Example: A Genesis boiler is rated at 1,300,000 Btu/hr. input at sea level. At an altitude of 5,000 (1500m), the prejet orifices will decrease the input rate by 20% (= 4% x 5) to a new rating of 1,040,000 Btu/hr. (= 80% x 1,300,000 Btu/hr.) The input reduction is achieved by the prejet orifices through self-regulation.

  • Page 6: Installation Instructions

    probe is not supplied with the GB models. A tank probe can be used as an option to control loop temperature and unit staging. Additionally, the Inlet Temperature Probe can be used as the loop thermostat in some heating (GB) applications. These types of controls connect to designated wires in the junction box at the rear of the boiler.
  • Page 7 • 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.

  • Page 8: Venting

    PROVIDED FOR PROPER COMBUSTION AND VENTILATION IN ACCORDANCE WITH THE NATIONAL FUEL GAS CODE, ANSI Z223.1 OR CAN/CSA-B149.1 AND .2 (LATEST EDITIONS) OR APPLICABLE PROVISIONS OF THE LOCAL BUILDING CODES. AN INSUFFICIENT SUPPLY OF AIR MAY RESULT IN A YELLOW, LUMINOUS BURNER FLAME, CARBONING OR SOOTING OF THE FINNED HEAT EXCHANGER, OR CREATE A RISK OF ASPHYXIATION.
  • Page 9 This is especially true in colder climates where ice buildup is likely to occur. A.O. Smith Corporation will not be held liable for any personal injury or property damage due to any dislodging of ice.
  • Page 10 STANDARD VENT - VERTICAL (CATEGORY I) IMPORTANT! VENT PRESSURE MUST BE MAINTAINED BETWEEN -0.02" W.C. AND -0.04" W.C. AT 24" (61.0 cm) ABOVE BOILER COLLAR. TABLE 7. STANDARD VERTICAL VENTING (CATEGORY I) APPLIANCE MODEL CATEGORY I000 1300 1500 1850 2100 2500 * Extending venting over 70 feet (21.3 m) may require special considerations.
  • Page 11 • Use only special gas vent pipes listed for use with Category III gas burning heaters, such as stainless steel Saf-T-Vent by Heat Fab, Inc., available from A.O. Smith WPC, 5621 W. 115th Street, Alsip, IL 60803 Phone: 1-800-433-2545 or Fax: 1-800-433-2515.
  • Page 12 DIRECT VENT - VERTICAL (CATEGORY I) TABLE 9. DIRECT VENT (VERTICAL EXHAUST CONFIGURATIONS) APPLIANCE CERTIFIED MODEL CATEGORY EXHAUST VENT SIZE (INCHES) EXHAUST VENT MATERIAL TYPE B OR I000 EQUIVALENT TYPE B OR 1300 EQUIVALENT 1500 TYPE B OR 1850 EQUIVALENT TYPE B OR 2100 EQUIVALENT...
  • Page 13 • Use only special gas vent pipes listed for use with Category III gas burning heaters, such as stainless steel Saf-T-Vent by Heat Fab, Inc. Inc., available from A.O. Smith WPC, 5621 W. 115th Street, Alsip, IL 60803 Phone: 1-800-433-2545 or Fax: 1-800-433-2515.
  • Page 14 STANDARD (VERTICAL) VENTING, CATEGORY I THIS BOILER MAY BE VENTED ACCORDING TO TABLE 7 (ALSO SEE FIGURE 5). AT LEAST TYPE B VENTING MUST BE USED WITH THE STANDARD VENTING OPTION (thru-the-roof) USING THE NATIONAL FUEL GAS CODE VENT TABLES.* TYPE B VENT PIPE CANNOT BE USED IF THE BOILER IS VENTED HORIZONTALLY OR AS A DIRECT VENT (SEE PAGES 11 THROUGH 13).

  • Page 15: System Installation

    SYSTEM INSTALLATION GENERAL If the system is to be filled with water for testing or other purposes during cold weather and before actual operation, care must be taken to prevent a down draft entering the boiler or freezing air from contacting the system.
  • Page 16 The fast response of A.O. Smith boilers eliminates any need to maintain boiler temperature when the system is satisfied. Wiring should always prevent firing of boiler(s) when there is no water flow in the mains.

  • Page 17: Hot Water Supply Installation

    mandatory but offers smooth, efficient operation of a modern system. Normal use of flow control valves is required to prevent cross circulation of zones as with any multiple pump system. Large systems with multiple boilers should include main water temperature controls (with or without outdoor reset) to sequence the boiler on and off, in relation to the load on the system.
  • Page 18 ONE GENESIS (MODEL GW) HOT WATER SUPPLY BOILER WITH HORIZONTAL TANK INSTALL THERMAL EXPANSION TANK COLD WATER SUPPLY LINE, IF CHECK VALVE OR PRESSURE REDUCING VALVE IS USED IN SUPPLY. DANGER TEMPERATURE SETTING SHOULD NOT EXCEED SAFE USE TEMPERATURE AT FIXTURES. SEE WATER TEMPERATURE CONTROL WARNING ON PAGE 23.
  • Page 19 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 21 2B. SIZING GAS SUPPLY LINE (For multiple installations of two or more boilers). See tables 13 (Natural Gas) and 14 (Propane Gas). TABLE 15. SINGLE UNIT INSTALLATION, SUGGESTED PIPE SIZE DISTANCE FROM METER BTU INPUT 0-50' 51-100' 101-200' 201-300' 301-500' 990,000 2" 1,300,000 2" 1,500,000 2" 1,850,000 2 1/2"...

  • Page 22: Operation

    At this time the user should not hesitate to ask the start-up technician any questions regarding the operation and maintenance of the unit. If you still have questions, please contact the factory or your local A.O. Smith representative. Make the Lighting and Operating instructions are included with this manual.
  • Page 23 PURGING OF GAS LINE Gas line purging is required with new piping or systems in which air has entered. CAUTION PURGING SHOULD BE PERFORMED BY PERSONS EXPERIENCED IN THIS TYPE OF GAS SERVICE TO AVOID RISK OF FIRE OR EXPLOSION. PURGE DISCHARGE MUST NOT ENTER CONFINED AREAS OR SPACES WHERE IGNITION CAN OCCUR.

  • Page 24: Lighting And Operating

    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.
  • Page 25 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.

  • Page 26: Control System

    CONTROL SYSTEM DESCRIPTION OF MULTI-STAGE FIRING SYSTEM The Central Control Board (CCB) is responsible for staging the Ignition Control Boards (ICB) and monitoring safety limit devices, control of circulation pump, power vent, alarm output and IRI gas valves (only on IRI models). The thermostat also resides on the CCB with inputs available for inlet, outlet and tank temperature probes as well as an input for a remote 24 VAC thermostat.
  • Page 27 Figure 15. Ignition Control Board Jumper Settings switch "D" on the Central Control Board is placed in the "ON" position, it will show the temperature at the tank probe. (See Figure 14.) The push buttons on the Display Board allow the user to program and view several system parameters described in the following text.
  • Page 28 Figure 16. Display Board High Gas Fail: Gas Pressure at Manifold too High LWCO: Low water Cutoff activated. Not enough water. Power Vent Fail: Not Enough Air to Close Switch Stage One: Failure on Stage One Stage Two: Failure on Stage Two Stage Three: Failure on Stage Three Stage Four: Failure on Stage Four Yellow Parameter Set Lights...
  • Page 29 Press the SELECT push-button on the display board until both the Set-Pt LED and Inlet Water Temperature LED (see Figure 16) are illuminated. The LED display will show the current set-point temperature. Press and hold the ADJUST push-button. The displayed temperature will either increase or decrease.
  • Page 30 Procedure for Setting Pump Delay The Controller is factory set with a 45 second post circulate function. With the Display Board, the user has the capability to choose between a 45, 90, or 180 second post circulate time period, or turn the pump on continuously.

  • Page 31: Preventative Maintenance

    drop out first followed by stages three, two and one. To achieve maximum efficiency, stages will reignite if the system water temperature drops below the stage Set Point minus the Set Point Differential. Note: Once a stage is satisfied, the blower associated with that stage will allow a 25 second postpurge before it deactivates.
  • Page 32 with this boiler should receive periodic (every six months) inspection to assure proper operation. A low water cutoff device of the float type should be flushed every six months. Periodic checks, at least twice a year, should be made for water and/or gas leaks. More frequent inspections may be necessary depending on water conditions.

  • Page 33: Troubleshooting

    CAUTION IF HEAT EXCHANGER MAINTENANCE REQUIRES TUBING REPLACEMENT, SPECIAL PROVISIONS SHALL BE TAKEN TO ENSURE THAT THE DAMAGED TUBES ARE CAREFULLY REMOVED. REPLACEMENT TUBES MUST BE PROPERLY INSTALLED AND EXPANDED INTO THE ROLLED TUBE TUB. OVER-ROLLING, MISALIGNMENT OF TUBES OR IMPROPER TIGHTENING OF THE ASSEMBLY MAY RESULT IN LEAKS OR DAMAGE TO THE HEAT EXCHANGER.
  • Page 34 For additional information please refer to the User’s Manual supplied with the boiler or contact: A.O. Smith Technical Services 7 a.m. to 7 p.m. Central Time at: 1-800-527-1953 Our Internet Site is another source of information 24 hours a day.

  • Page 35: Limited Warranty

    A. O. Smith Corporation, the warrantor, extends the following LIMITED WARRANTY to the owner of this hydronic boiler: 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.

  • Page 36: Wiring Diagram/Schematic

    REPLACEMENT PARTS 5621 W. 115TH STREET, ALSIP, IL 60803 Phone: 800-433-2545 Fax: 800-433-2515 www.hotwater.com E-Mail: parts@hotwater.com...

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