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INSTALLATION & OPERATING
For All A2000 Series Water
Heaters & Water Boilers
WARNING:
If these instructions are not followed exactly, a fire or explosion may result causing
property damage, personal injury or death.
FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors and liquids or
other combustible materials in the vicinity of this or any other appliance. To do so may result in
an explosion or fire.
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.
Note: Place a copy of these instructions adjacent to the boiler/heater; notify the owner to keep for future reference.
If Shipping Damage is noted, receiver must make damage claim on Bill of Lading (see page 6).
INSTRUCTIONS
918 West Walnut St. Danville, Kentucky 40422
Visit Us On The Web:
For Customer Service Please Call: 859-236-3181
W3260001 Rev. D Effective May, 2011
www.gbt-inc.com
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Summary of Contents for GBT A2-035
- Page 1 If Shipping Damage is noted, receiver must make damage claim on Bill of Lading (see page 6). 918 West Walnut St. Danville, Kentucky 40422 Visit Us On The Web: www.gbt-inc.com For Customer Service Please Call: 859-236-3181 W3260001 Rev. D Effective May, 2011...
- Page 2 SAFETY Safety messages and instructions located in this manual and on the heater/boiler provide warnings to you and others of potential hazards. Before installing, operating or servicing this heater/boiler, it is important to read and understand these safety instructions and messages. The safety alert symbol alerts you to potential hazards.
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Page 3: Table Of Contents
TABLE OF CONTENTS INTRODUCTION …………………………………………………………………………… 4 General Dimensions & Specifications Model Identification Ratings & Certifications INSTALLATION ……………………………………………………………………………. 6 Product Receipt High Elevation Location & Placement Combustion Air Requirements Electrical Requirements Gas Requirements Water Connections Venting System START-UP & OPERATION ……………………………………………………………... 15 Pre-Start Checklist Filling The System With Water Purging Air From Gas Lines... -
Page 4: Introduction
The unique design of the appliance provides excellent heat transfer and a small footprint. The heat exchanger resists build-up of lime scale and allows de-liming without disassembly of the unit. DIMENSIONS & SPECIFICATIONS Model A2-035 17 ½ 34 ½ A2-050 16 ½... -
Page 5: Model Identification
MODEL IDENTIFICATION The model number can be found on the Name Plate label, located on the heater/boiler. A2 - (H,X,B,T,C) - (###) - (NG,LP,NH,LH) A2 = A2000 Series Water Heater or Boiler Water Heater Water Heater with 2-Stage burner controls Boiler Boiler with 2-Stage burner controls Boiler with ASME CSD-1 controls... -
Page 6: Installation
INSTALLATION This manual must be thoroughly reviewed and understood before installing your A2000 heater/boiler. Installation and Service must be completed by a Qualified Installer, Service Agency or Qualified Gas Supplier. If you have any questions which are not covered in the manual, please contact Green Boiler Technologies or your local representative. -
Page 7: Location & Placement
LOCATION & PLACEMENT When installing the boiler or heater, consideration must be given to proper location. In addition to the following requirements, the installation must adhere to all local or state code requirements. 1. The unit should be leveled. 2. Minimum clearance for hot water pipes and venting from combustible material is 6 inches. 3. -
Page 8: Electrical Requirements
When air is taken directly from the outdoors or through a vertical duct, each opening must have a minimum of 1 square inch (6.5 cm ) per 4,000 Btu/hour. If a horizontal duct is used, each opening must have a minimum of 1 square inch per 2,000 Btu/hour is required. -
Page 9: Gas Requirements
mounted in the lower half of the storage tank. Boiler temperature controls are typically mounted in the primary loop. If the temperature control sensor is mounted directly on the heater/boiler water piping, the sensor must be installed on the inlet water piping to prevent short cycling of the appliance. A water flow switch must be installed by the installer and wired to prevent the unit from firing if for any reason there is an inadequate flow of water through the boiler/heater (see wiring diagrams for suggested location in the electrical circuit). - Page 10 Maximum Pressure Minimum Pressure Natural Gas Propane Units: Inches of Water The A2000 series water boiler/heater is not intended to operate at a gas supply pressure other than shown on the rating plate. Exposure to a higher gas supply pressure may cause damage to the gas valves, which can result in fire or explosion. The gas supply piping must have a 3 inch (7.6 cm) minimum sediment trap (sometimes referred to as a dirt trap or drip leg) and a manual shut off valve ahead of the boiler/heater.
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Page 11: Water Connections
80 C) temperature rise through the heater/boiler. Flow Rate (gpm) Vs. Water Temperature Rise Temp Rise A2000 Model Flow Switch deg F deg C A2-035 A2-050 A2-070 A2-097 A2-120 A2-140 10.0 Recommended Temperature Rise: 20 - 45 When used for both potable water heating and space heating, all piping and components connected to the system for space heating must also be suitable for use with potable water. - Page 12 The maximum flow rate through the A2000 heat exchanger is 56 gpm due to velocity induced tube erosion. Head Loss (ft hd) Vs. Water Flow Rate Through Heat Exchanger (Approximate) Flow A2000 Model (gpm) A2-035 A2-050 A2-070 A2-097 A2-120 A2-140 22.5...
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Page 13: Venting System
A2000 models are designed to operate with a negative pressure in the exhaust venting. This appliance • is NOT approved for side-wall venting. Consult your GBT representative or Customer Service if side- wall venting is required. When any horizontal vent extends for more than 6 feet (1.8 meter), vent supports must be installed with •... - Page 14 subsequent supports after every additional 6 feet. The support must be secured using at least #10 fasteners to a solid material (solid masonry or wood framing or blocking). Do not fasten to drywall sheathing using hollow wall anchors. As an alternative, a threaded rod and trapeze support in accordance with SMACNA HVAC Construction Standards –...
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Page 15: Start-Up & Operation
1. Ensure the manual gas valve upstream of the heater/boiler is CLOSED. 2. For A2-035 and A2-050 models, ensure the main regulating gas valve is closed. Before turning on the power to this appliance smell all around the appliance for gas. Be sure to smell next to the floor because some gas is heavier than air and will collect near the floor. - Page 16 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. •...
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Page 17: Start-Up
7. Check the manifold gas pressure downstream of the automatic gas valves using the outlet pressure tap provided on the gas valve (A2-035 and 050 models only) or the pressure tap provided in the gas piping. For Natural Gas models, the manifold pressure should be set to 4.0” water column. -
Page 18: Shut-Down Procedure
Main Burner Flame Pilot Burner Flame 9. Verify the water flow switch opens at the minimum water flow rate by slowly closing a manual ball valve installed in the water outlet piping, until the difference between the water inlet and outlet reaches 95 – F (53 –... -
Page 19: Operation
OPERATION The A2000 models are simple ON/OFF water heater/boilers. The units are turned ON and OFF by the application or removal of 120 VAC power to the control panel. Normally, this 120 VAC power is provided through an operating thermostat. Safety controls (such as a flow switch and manual reset water high limit temperature switch) installed between the operating thermostat and the heater/boiler prevent power from reaching the control panel if water flow is not present, or the outlet water temperature has been exceeded. - Page 20 Water High Limit Switch – Maxitrol Gas Pressure Regulator Manual Reset Gas Pressure Regulator: A gas pressure regulator is provided on all A2000 water heater/boilers. This regulator is preset at 4 inches water column for natural gas or 10.5 inches water column for Propane gas. For A2(H,B)035/050 models, the pressure may be adjusted using the adjustment screw located on the combination gas valve (see Figure on page 16).
- Page 21 A2000 Pump Selection Chart MODEL: A2*035* A2*050* A2*070* A2*097* A2*120* A2*140* Flow Rate & 23GPM @ 23GPM @ 40GPM @ 49GPM @ 54GPM @ 40GPM @ Head Loss 11.3 FT. 11.3 FT. 34.6 FT. 54.8 FT. 70.7 FT. 70.7 FT. Pump Vendor GOULDS : 1ST2C1D4...
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Page 22: Operation
Relief Valve Operation: Each boiler/water heater is equipped with an ASME approved pressure relief valve, with a standard setting of 125 psi (862 kPa). The outlet of the relief valve must be piped to a drain or other suitable safe place in accordance with local codes. When the heater/boiler is connected to a storage tank, a separate temperature/pressure relief valve must be provided on the tank. -
Page 23: Maintenance & Inspection
MAINTENANCE & INSPECTION This manual must be thoroughly reviewed and understood before servicing your A2000 heater/boiler. Installation and Service must be completed by a Qualified Installer, Service Agency or Qualified Gas Supplier. If you have any questions which are not covered in the manual, please contact Green Boiler Technologies or your local Representative. -
Page 24: Burner & Flue Passageway
Smoke Test – Place a source of smoke or other visible fumes below the opening of the draft hood. If the fumes are all drawn up the draft hood opening, the appliance is drafting properly. If any fumes roll outside of the vent hood there is a problem with the drafting or make-up air. Draft Gauge –... -
Page 25: Removal Of Existing Appliance
Removal of Existing Appliance: If an existing appliance is removed from a common venting system, the common venting system is likely to be too large for proper venting of the appliances remaining connected to it. At the time of removal, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation. -
Page 26: Troubleshooting
TROUBLESHOOTING SYMPTOM POSSIBLE CAUSE CHECKS & REMEDIES Short Cycling (Unit Operating Aquastat Not Install An Operating Aquastat Or Boiler Sequencer To Turns ON And OFF Installed Control The Water Temperature Every 30 seconds Or So). Operating Aquastat For a Storage Tank Installation, Install the Operating Installed In The Wrong Aquastat in the Tank. - Page 27 SYMPTOM POSSIBLE CAUSE CHECKS & REMEDIES Pilot Burner Not The Ignition Module Is Verify That The Red Spark Cable Is Securely Attached To Lighting Not Generating A Spark The Ignition Module And The Pilot Burner. Verify The Red Spark Cable Is Not Cracked Or Broken. Replace If Necessary.
- Page 28 SYMPTOM POSSIBLE CAUSE CHECKS & REMEDIES The Pilot Is Lit And The Bleed Line On One (Only For Honeywell V88 Gas Valves) Temporarily Stays ON, But The Of The Gas Valves Is Disconnect The 1/8” Bleed Line From Each Gas Valve. If Main Burner Never Plugged The Appliance Operates Properly, Clear Or Replace The...
- Page 29 SYMPTOM POSSIBLE CAUSE CHECKS & REMEDIES The Flow Switch Water Flow Rate Too Ensure Valves In The Water Lines Are Open Keeps Tripping Or Will Not Close Ensure The Pump Is Operating Correctly. Replace Or Upgrade Pump If Required. Excessive Scaling The Heat Exchanger Should Be De-limed.
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Page 30: Diagrams
DIAGRAMS Page 29... - Page 31 Page 30...
- Page 32 FEEDBACK LOOP (BY-PASS) PLUMBING FOR LOW TEMPERATURE SYSTEMS 1. Set Operating (Controlling) Thermostat to the desired return temperature. 2. Open all water valves. 3. Watch the temperatures at Thermometer ‘A’ and the T&P Gauge on the Heater/Boiler Outlet. 4. Adjust valve ‘B’ in small increments until the temperature reading at the T&P Gauge is about 80 higher than the temperature measured at Thermometer ‘A’.
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Page 33: Wiring Diagram
WIRING DIAGRAM A2000 Water Heater Models Page 32... - Page 34 WIRING DIAGRAM A2000 Boiler Models Page 33...
- Page 35 WIRING DIAGRAM A2000 CSD-1 Boiler Models Page 34...
- Page 36 A2000 WITH CONSTANT PUMP OPERATION A2000 WITH ON-OFF PUMP OPERATION Page 35...
- Page 37 A2000 WITH INFITEC PUMP DELAY Page 36...
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Page 38: Parts List
A2000 PARTS LIST Gas Train, Components Differ By Model Page 37... - Page 39 W2500007 Burner Orifice, Blank High Altitude Models, Drill To Order W2500006 Burner Orifice, Special Stainless Steel All Models, Drill To Order W1800002 Burner With Orifices, A2-035-NG A2-035-NG W1800011 Burner With Orifices, A2-035-LP A2-035-LP W1800003 Burner With Orifices, A2-050-NG (2 Req)
- Page 40 DESCRIPTION USE ON MODEL W1950023 Pilot Burner Assembly, NG All NG Models W5501112 Pilot Burner Assembly, LP All LP Models W4501050 Pilot Mounting Bracket, A2-035 A2-035 W4501051 Pilot Mounting Bracket, A2-050 A2-050 W4501052 Pilot Mounting Bracket, A2-070 A2-070 W4501053 Pilot Mounting Bracket, A2-(097-140)
- Page 41 A2000 PARTS LIST - Continued PART NUMBER ITEM DESCRIPTION USE ON MODEL W5501066 Heat Exchanger Assy A2-035 * A2-035 W5501067 Heat Exchanger Assy A2-050 * A2-050 W5501068 Heat Exchanger Assy A2-070 * A2-070 W5501069 Heat Exchanger Assy A2-097 * A2-097...
- Page 42 This warranty does not cover any freight, labor, installation or removal costs, either for its original purchase or its replacement. GBT does not assume liability for any permits, loss of time, consequential damages or contingent liability of any kind resulting from the manufacture, sale, installation or use of this water heater.
- Page 43 This warranty does not cover any freight, labor, installation or removal costs, either for its original purchase or its replacement. GBT does not assume liability for any permits, loss of time, consequential damages or contingent liability of any kind resulting from the manufacture, sale, installation or use of this water boiler.
- Page 45 All claims for damage or shortage must be filed with the carrier by the customer. 918 West Walnut St. Danville, Kentucky 40422 Visit Us On The Web: www.gbt-inc.com For Customer Service Please Call: 859-236-3181 W3260001 Rev. D Effective May, 2011...
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