A.O. Smith 400 Instruction Manual
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A.O. Smith 400 Instruction Manual

A.O. Smith 400 Instruction Manual

400 series; 401 series; 402 series; 403 series; 404 series; 405 series
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See also: Operation & Installation Manual
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. 0906

Instruction Manual

GB/GW
1000, 1300, 1500, 1850, 2100, 2500
SERIES: 400, 401, 402, 403, 404, 405
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
DIMENSIONS/CAPACITIES DATA .......................... 2 - 3
FOREWORD ......................................................... 4 - 5
FEATURES/CONTROLS ..................................... 5 - 7
INSTALLATION INSTRUCTIONS ....................... 7 - 9
VENTING ........................................................... 9 - 11
SYSTEM INSTALLATION ................................ 11 - 16
HYDRONIC INSTALLATION ............................ 16 - 18
HOT WATER SUPPLY INSTALLATION ........... 18 - 31
GAS CONNECTIONS ...................................... 18 - 23
OPERATION .................................................... 31 - 34
LIGHTING AND OPERATING .......................... 32 - 33
CONTROL SYSTEM ....................................... 34 - 44
PREVENTATIVE MAINTENANCE .................. 44 - 46
TROUBLE SHOOTING .................................... 42 - 44
WIRING DIAGRAM/SCHEMATIC ................... 24 - 27
LIMITED WARRANTY ............................................. 47
MC BEE, SC., RENTON, WA.,
STRATFORD-ONTARIO, VELDHOVEN-THE NETHERLANDS,
www.hotwater.com / email:parts@hotwater.com
1
:
MODELS
CAUTION
NANJING, CHINA
PAGE
212511-000

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Summary of Contents for A.O. Smith 400

  • Page 1: Table Of Contents

    PRINTED IN U.S.A. 0906 Instruction Manual GB/GW MODELS 1000, 1300, 1500, 1850, 2100, 2500 SERIES: 400, 401, 402, 403, 404, 405 CAUTION TEXT PRINTED OR OUTLINED IN RED CONTAINS INFORMATION RELATIVE TO YOUR SAFETY. PLEASE READ THOROUGHLY BEFORE INSTALLING AND USING THIS APPLIANCE.

  • Page 2: Dimensions/Capacities Data

    DIMENSIONS/CAPACITIES DATA TOP VIEW FRONT VIEW TABLE 1: GAS AND ELECTRICAL REQUIREMENT 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 DIMENSIONS DATA FOR OUTDOOR CONFIGURATION REAR VIEW FRONT VIEW TABLE 3. DIMENSIONAL DATA Model Inches cm Inches GBO/GWO-1000 35.5 31.6 80.3 GBO/GWO-1300 24.75 62.9 31.6 80.3 GBO/GWO-1500 76.2 31.6 80.3 GBO/GWO-1850 27.5 69.9 32.3 GBO/GWO-2100 78.7 32.3 GBO/GWO-2500 96.5 32.3 Figure 2.

  • Page 4: Foreword

    TABLE 4: 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 5: PUMPING PERFORMANCE GUIDE GB MODELS-FLOW, HEAD LOSS AND TEMPERATURE RISE 20 Deg.

  • Page 5: Control System

    GROUNDING INSTRUCTIONS This boiler must be grounded in accordance with the National Electrical Code, NFPA 70 or the Canadian Electrical Code CSA 2 C22.1 and/or local codes. The boiler is polarity sensitive, correct wiring is imperative for proper operation. This boiler must be connected to a grounded metal, permanent wiring system, or an equipment grounding conductor must be run with the circuit conductors and connected to the equipment grounding terminal or lead on the boiler.

  • Page 6: Hydronic Installation

    DIFFERENTIAL PRESSURE SWITCH The differential pressure switch ensures that a sufficient differential exists between the air pressure in the pre-mix chamber and the inlet of the burner for safe, combustion and proper low NO x emission. The switch has two pressure taps marked "+" (positive) and "-" (negative). Silicone tubing is run from the positive pressure tap of the switch to a tap on the control panel to measure the air pressure in the pre-mix chamber.

  • Page 7: Safety Relief Valves

    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.
  • Page 8 the authority having jurisdiction, must be provided with a low water cutoff device either as a part of the boiler or at the time of boiler installation. WARNING UNDER NO CIRCUMSTANCES SHOULD THE EQUIPMENT ROOM WHERE THE BOILER IS INSTALLED EVER BE UNDER NEGATIVE PRESSURE.

  • Page 9: Venting

    If the confined space is within a building of tight construction, air for combustion, ventilation, and draft hood dilution must be obtained from outdoors. When directly communicating with the outdoors or communicating with the outdoors through vertical ducts, two permanent openings, located in the above manner, shall be provided.

  • Page 10: Horizontal Vent Installation

    the exhaust vent pipe must be listed for use with category III gas burning heaters such as "Saf-T-Vent" manufactured by Heat-Fab Inc. This vent system must be 100% sealed with a condensate trap located as close to the boiler as possible. When sizing exhaust piping and intake air piping, 90-degree elbows are equivalent to 10 feet (3.1 m) of straight pipe and 45-degree elbows are equal to 5 feet (1.5 m) of straight pipe.

  • Page 11: System Installation

    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 12 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 10. 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 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., available from A.O. Smith, 500 Tennessee Waltz Parkway, Ashland City, TN 37015 Phone: 1-800-433-2545 or Fax: 1-800-433-2515. Pipe joints must be positively sealed.
  • Page 14 TABLE 12. DIRECT VENT (VERTICAL EXHAUST CONFIGURATIONS) APPLIANCE CERTIFIED MODEL CATEGORY EXHAUST VENT MATERIAL TYPE B OR I000 EQUIVALENT TYPE B OR 1300 EQUIVALENT 1500 TYPE B OR 1850 EQUIVALENT TYPE B OR 2100 EQUIVALENT TYPE B OR 2500 EQUIVALENT •...
  • Page 15 • 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, 500 Tennessee Waltz Parkway, Ashland City, TN 37015 Phone: 1-800-433-2545 or Fax: 1-800-433-2515.

  • Page 16: Hydronic Installation

    volume may result in condensation within the boiler on cold starts. This condensing of water vapor in the combustion area can be prevented if a portion of the system water flow is diverted past the boiler to cause an increase in boiler temperature. BYPASS BALANCING With systems where water temperature can be expected to drop appreciably due to long standby periods, or heavy draw down, a...

  • Page 17: Space Heating Applications

    This bypass may also be used with multiple boilers manifolded for reverse-return flow. The system bypass would be installed from boiler outlet to suction side of pump. The boiler piping system of a hot water heating boiler connected to heating coils located in air handling units where they may be exposed to circulating refrigerated air, must be equipped with flow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle.

  • Page 18: Hot Water Supply Installation

    related to approximate water volume of the system. The system should be turned on to circulate water mix for about one hour and then flush clean with fresh water. Before operating the boiler, the entire system must be filled with water, purged of air and checked for leaks.
  • Page 19 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 26.
  • Page 20 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 WATER FLOW SWITCH PROTECTS THE BOILER IN CASE OF WATER SERVICE INTERRUPTION OR CIRCULATOR FAILURE.
  • Page 22 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.
  • Page 23 GAS MANIFOLD ASSEMBLY GB/GW 1850 GB/GW 1000 - 1500 GB/GW 2100 GB/GW 2500 Figure 14. GB/GW 1000 - 2500 Gas Manifold Assembly Diagrams.
  • Page 28 Figure 17. CCB CENTRAL CONTROL BOARD...
  • Page 29 Figure 18. FCB FLAME CONTROL BOARD Diagram...
  • Page 30 Figure 19. PDB POWER DISTRIBUTION BOARD Diagram...

  • Page 31: Operation

    Fuse Protection The 24VAC circuitry is protected with a 3 amp fuse on the Flame Control Boards (FCB) and a 7.5 amp fuse on the Central Control Board. If the fuse opens, a red LED located near the fuse will light. See Figures 17 and 18.

  • Page 32: For Your Safety Read Before 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 33 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 34: Manifold Pressure

    MANIFOLD PRESSURE The manifold gas pressure is measured at the pressure tap on the downstream side of the combination gas valve(s). For natural gas the Manifold Pressure should measure 3.5" W.C. For propane (LP) gas, the pressure should read 10" W.C. IMPORTANT UNDER NO CIRCUMSTANCES SHALL THE GAS PRESSURE MEASURED AT THE BURNER MANIFOLD EXCEED THAT STATED...
  • Page 35 required): The CCB accepts analog temperature inputs from up to three sensors (inlet, outlet and tank). • ECO input (CCB - required): The ECO (energy cut off) is a hi-limit switch, which is located inside the outlet probe. It is a normally closed switch that opens if the probe is exposed to a temperature higher than the trip point.
  • Page 36 CCB - Ten Position Dipswitch (Central Control Section) SW1: Dipswitch configurations are READ ONLY ON POWER UP. These switches are only to be set at the factory or by authorized trained personnel! Once set the boiler will operate according to the chosen options. If a switch is changed, power must be cycled before the change will take effect.

  • Page 37: Operating Sequence

    FCB: Eight-Position Dipswitch The first three switches are similar to the switch setup of SW2 on the CCB. The remaining five switches are required for the function of igniter, blower, flame detection, and to address the firing stage. NOTE: When switch 5 is set to OFF (no blower), switch 3 (blower speed) is ignored.
  • Page 38 followed by 15-second inter-purge period, then the system returns to step 7, if the "Trial for Ignition" dipswitch is set for three (3) tries. If the dipswitch is set for one (1) trial, the system will declare an error and boiler will require resetting the control. 10.
  • Page 39 The following status information is displayed from the Status Displayed *(True Condition) Outlet temperature too high LW/CO Water Level low Blk Flue Flue blocked Flow Water flowing Low Gas Gas pressure low Tstat Thermostat requesting heat Hi Limit Outlet temp exceeds High Limit setpoint Pump Pump output activated IRI Gas Pwr...
  • Page 40 • Soft Fault State: (See "Fault Description" section for list of soft and Auto Reset faults.) The CCB turns off the Powered Vent and the IRI Gas. The pump remains on for the selected post-circulate time to cycle the hot water out of the boiler.

  • Page 41: Operating Setpoint Adjustment Procedure

    OPERATING SETPOINT ADJUSTMENT PROCEDURE The system has a standard programmable Operating Setpoint range of 70 Degrees F to 190 Degrees F for a GW and of 70 Degrees F to 220 Degrees F for a GB for either tank or inlet probe depending on selection.

  • Page 42: Troubleshooting Ignition System

    when an error is detected. It will also go to this screen upon power-up if an error was still valid when power was turned off. NOTE: Errors are cleared from this screen by pressing the "select" key. • Error History Screen: This screen displays a list of the last 9 errors (with time stamps) that have occurred.
  • Page 43 “Low 24VAC” Voltage from transformer less than 18 vac Check transformer output. Should be over 24vac. May be caused by excessive current drain or a faulty transformer “Brown Out Reset” Indicates a brown out reset occurred Caused by a momentary dip in voltage on the CCB +5vdc power bus. Contact factory. (Not considered a serious problem if it only occurs on very rare occasions.) “Timeout Reset”...

  • Page 44: Preventative Maintenance

    “Tank Probe” Tank (Remote) probe shorted or open Caused when the thermistor in the probe or the wiring is shorted or disconnected. Check the probe. Note: the thermistor and wiring can be checked by disconnecting the probe from the CCB and reading the resistance across the two active pins on the connector at the end of the probe cable.
  • Page 45 After placing the boiler in operation, check the ignition system safety shut-off devices for proper operation. To accomplish this with the main burners operating, close the valve on the manifold. Within four seconds the main burners should extinguish. If this does not occur immediately, discontinue gas supply by closing main manual shut-off and call a qualified serviceman to correct the situation.
  • Page 46 all of the hardness (lime). For this reason it is recommended that a regular schedule for deliming be maintained. The time between cleaning will vary from two to six months depending upon water conditions and usage. A change of approximately 5 F (3°C) in the normal temperature rise through the boiler is usually an indication that scale should be removed.

  • Page 47: Limited Warranty

    (6) at a water velocity flow rate, not exceeding or below the Boiler's designed flow rates; (7) in properly sized piping system in accordance with A.O. Smith WPC sizing guidelines. Any accident to the boiler, any misuse, abuse (including freezing) or alteration of it, any operation of it in a modified form will void this warranty.
  • Page 48 500 Tennessee Waltz Parkway, Ashland City, TN 37015 Phone: 800-433-2545 www.hotwater.com E-Mail: parts@hotwater.com...

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