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1.

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.

2.

The LED display will show the current set-point temperature.

3.

Press and hold the ADJUST push-button.  The displayed
temperature will either increase or decrease.  To alternate
between increasing or decreasing the temperature, release
then press and hold the ADJUST push-button.

4.

When the desired set-point temperature is reached, release
the ADJUST push-button.

5.

Press the ENTER/RESET push-button once, this enters the
selected set-point temperature into controller memory.

6.

The appliance will now control the temperature to the desired
set-point value.

7.

For setting the stage differentials, see the section labeled
Procedure for Setting Stage Differential.

NOTE:

The boiler must complete a full cycle in order for the

new setting to take effect.  If the unit is turned off prior
to a complete cycle the setting will be lost and the
 previous setting will remain in effect.

24 VAC System Controller (Optional)

A 24 VAC thermostat/aquastat can be implemented as a system
controller on Genesis units.  The connection for such devices is
located in the 24 VAC junction box at the rear of the unit.  A 24 VAC
thermostat/aquastat can only be used as an "On/Off" switch for the
unit.  The actual controlling of the staging will be through either the
inlet or tank probe.  To use a 24 VAC system controller, dip switch "E"
on the CCB must be switched to the "on" position.  See Figure 14.

Tank Probe (Optional)

In addition to the Inlet and Outlet/ECO Probes, units can be
optionally equipped with a tank Probe.  The connection for the tank
probe is located in the 24 VAC junction box at the rear of the unit.
The tank Probe can be configured to control the staging of the unit.
See Tank Probe Installation section on page 17 for additional
information.

 Procedure for Setting Tank Probe Temperature

If you have a GW hot water supply boiler, and have installed the tank
probe, below are the instructions on how to adjust the water
temperature set-point.

1.

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.

2.

The LED display will show the current set-point temperature.

3.

Press and hold the ADJUST push-button.  The displayed
temperature will either increase or decrease.  To alternate
between increasing or decreasing the temperature, release
then press and hold the ADJUST push-button.

4.

When the desired set-point temperature is reached, release
the ADJUST push-button.

5.

Press the ENTER/RESET push-button once, this enters the
selected set-point temperature into controller memory.

6.

The appliance will now control the temperature to the desired
set-point value.

7.

For setting the stage differentials, see the section labeled
Procedure for Setting Stage Differential.

Procedure for Setting Stage Differential

Once the system control and set-point temperature has been
entered, the switching differentials for the staging of the unit must

be established.  To facilitate proper operation and maximize
appliance performance, each stage has a programmable
operating switching differential or “hysteresis” about the set point.
This means a call for heat for a particular stage will become active
when the water temperature measured at the controlling
temperature sensing probe drops to the set-point value minus the
switching differential value.  It is necessary to set three set-point
differential values for three stage units and four for four stage.  The
burner will remain on until the water temperature measured at
controlling probe reaches the stage set-point value.  The switching
differential value is fully programmable from 0° F to 20°F (0°C to
11°C) using the push-button(s) located on the Display Board.

To change or view the current programmed switching differential:

1.

Press the SELECT push-button on the display board until both
the Set-Pt Diff. and green Stage One LED (see Figure 16) are
illuminated.

2.

The LED display will show the current differential for stage
one.

3.

Press and hold the ADJUST push-button.  The displayed value
will either increase or decrease.  To alternate between
increasing or decreasing the differential, release then press
and hold the ADJUST push-button.

4.

When the desired Set-Pt differential is reached, release the
ADJUST push-button.

5.

Press the ENTER/RESET push-button once, this enters the
selected set-point deferential into controller memory.  To view
the Set-Pt minus the Set-Pt differential, press and hold the
"ENTER" push-button.  This will be the "turn-on" temperature
for Stage One and the "turn-off" temperature for Stage Two.

6.

Repeat steps 2 through 5 for the rest of the stages.

7.

The appliance will now control temperature utilizing the
desired differentials.

Example:
Application: 

Hydronic Heating

Desired System Temperature:

  185°F (85°C)

Stage Differentials:  

5°F (3°C) per Stage.

Note:  The user must first choose which probe is to control the
staging of the unit.  The controlling probe will be either the inlet or
tank probe.  (If the tank probe is used to regulate loop temperature
in hydronic applications (GB Models), make sure it is located on
the return side of the closed loop.)  Use Dip Switch "D" on the
Central Control Board to make this selection.  See Figure 14.

Set the stage differentials using the procedure described in the
Procedure for Setting Stage Differential section of the document.
Setting the control as described in the above example (5°F
differentials for each stage) will give the following stage set-points.

Stage One

Off Temperature: 185°F (85°C)

On Temperature: 180°F (82°C)

Stage Two

Off Temperature:  180°F (82°C)

On Temperature:  175°F (79°C)

Stage Three

Off Temperature: 175°F (79°C)

On Temperature: 170°F (77°C)

Stage Four

Off Temperature: 170°F (77°C)

On Temperature: 165°F (74°C)

Summary of Contents for 200 Series

Page 1: ...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 PAGE ROUGH INDIMENSIONS CA...

Page 2: ...Type of Gas Inches W C kPa Volts Hz Amperes GW GB 1000 thru 2500 NATURAL 3 5 0 87 120 60 30 GW GB 1000 thru 2500 PROPANE 10 2 49 120 60 30 All Models Maximum Supply Pressure 14 0 In W C 3 49 kPa Mini...

Page 3: ...2 27 7 33 3 38 8 44 4 50 55 5 61 1 66 7 72 2 GW 1000 990 000 290 1 LPH 9526 7620 6350 5443 4763 4234 3810 3462 3175 2930 GPH 2520 2016 1680 1440 1260 1120 1008 916 840 775 GW 1300 1 300 000 380 9 LPH...

Page 4: ...d by a rate of 4 for each 1 000 feet 300 m above sea level FOREWORD These designs comply with the latest edition of the American National Standards for Gas Fired Low Pressure Steam and Hot Water Boile...

Page 5: ...ignition trials the boiler will lock out Upon lockout manually push the ENTER RESET button on the display panel to restart the boiler WATER FLOW SWITCH The Water Flow Switch is installed at the boiler...

Page 6: ...SUCH THAT IT NATURALLY DRAINS ITSELF If any safety relief valve is replaced the replacement valve must comply with the latest version of the ASME Boiler and Pressure Vessel Code Section IV HEATING BO...

Page 7: ...waxes and process chemicals are typical compounds which are corrosive These materials are corrosive at very low concentration levels with little or no odor to reveal their presence Products of this s...

Page 8: ...1 square inch per 14 000 BTU in excess of 1 000 000 BTUH This opening s shall be located at or ducted to a point neither more than 18 46 0 cm nor less than 6 inches 15 2 cm above the floor level Where...

Page 9: ...he combustion process horizontal terminations must not be located over areas of pedestrian or vehicular traffic i e public walkways or over areas where condensate could create a nuisance or hazard Thi...

Page 10: ...ortion of the vent shall be supported to maintain clearances and to prevent physical damage or separation of joints TABLE 7 STANDARD VERTICAL VENTING CATEGORY I Extending venting over 70 feet 21 3 m m...

Page 11: ...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 8...

Page 12: ...boiler to the vent terminal The horizontal portion of the vent shall be supported to maintain clearances and to prevent physical damage or separation of joints Figure 7 APPLIANCE CERTIFIED EXHAUSTVENT...

Page 13: ...800 433 2515 Pipe joints must be positively sealed TABLE 10 DIRECT VENT HORIZONTAL EXHAUST CONFIGURATIONS Figure 8 APPLIANCE CERTIFIED VENT MAXIMUM AIRINTAKE AIRINLET MAXIMUM MODEL CATEGORY EXHAUSTVEN...

Page 14: ...he Installed vent be airtight Please insure that all joints are sealed properly during installation DIRECTVENTVERTICALANDHORIZONTALVENTING For direct vent applications this boiler may be vented accord...

Page 15: ...minimum pressure drop for several circuits manifolds should be larger than system loops SYSTEM INSTALLATION GENERAL If the system is to be filled with water for testing or other purposes during cold w...

Page 16: ...g that is desired A single boiler installation might be controlled directly from space temperature thermostat s Multiple boiler installations are more effective when the boilers are sequenced in and o...

Page 17: ...ance loop must be installed see figures 11 and 13 HARD WATER CONDITIONS Where hard water conditions exist water softening or the threshold type of water treatment is recommended This will protect the...

Page 18: ...l tank IMPORTANT SAFETY FLOW SWITCH PROTECTS THE BOILER IN CASE OF WATER SERVICE INTERRUPTION OR CIRCULATOR FAILURE PIPE TO OPEN DRAIN X FACTORY INSTALLED ON UNIT SUPPLIED WITH UNIT FIELD INSTALLED IN...

Page 19: ...ED DANGER TEMPERATURE SETTING SHOULD NOT EXCEED SAFE USE TEMPERATUREAT FIXTURES SEE WATER TEMPERATURE CONTROL WARNING ON PAGE 23 IF HIGHER PREHEAT TEM PERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTE...

Page 20: ...92 2 841 2 577 2 372 2 197 2 109 1 962 1 757 1 611 1 464 1 347 Length of Pipe in Feet Metres Nominal Iron Pipe Size Cap 10 Ft 20 Ft 30 Ft 40 Ft 50 Ft 60 Ft 70 Ft 80 Ft 90 Ft 100 Ft 125 Ft 150 Ft 175 F...

Page 21: ...ted Rating Input Number of Model BTUH Burners Natural Holes Propane Holes GB GW 1000 990 000 10 0 111 4X 0 071 3X GB GW 1300 1 300 000 13 0 111 4X 0 071 3X GB GW 1500 1 500 000 15 0 111 4X 0 071 3X GB...

Page 22: ...th a 10 amp fuse located inside the control box Note Four extra 3 amp fuses and one 5 amp fuse are supplied with the boiler Recommended Replacement fuses 3 Amp Littlefuse automotive fuse PN 257003 5 A...

Page 23: ...ssure should read 10 W C IMPORTANT UNDER NO CIRCUMSTANCES SHALL THE GAS PRESSURE MEASUREDATTHE BURNER MANIFOLD EXCEED THAT STATED ON THE BOILER RATING PLATE OVERFIRING WILL RESULT IN DAMAGE TO THE BOI...

Page 24: ...5 MINUTES TO CLEAR OUTANYGAS THEN SMELLFORGAS INCLUDINGNEARTHEFLOOR IFYOU SMELLGAS 1 SET THE SYSTEM CONTROLLER TO THE LOWEST SETTING 2 TURN POWER SWITCH ON APPLIANCE TO OFF POSITION 3 REMOVEACCESS PAN...

Page 25: ...FIEDSERVICE TECHNICIAN TO INSPECT THE APPLIANCE AND TO REPLACEANYPARTOFTHECONTROLSYSTEMANDANY GASCONTROLWHICHHASBEENUNDERWATER E DO NOT OPERATE APPLIANCE UNLESS UNIT IS FILLED WITH WATERAND WATER LINE...

Page 26: ...TER RESET enable the user to adjust set points differentials post circulate time reset the cycle count and reset the control system during lock out Changes made to programmable features are stored in...

Page 27: ...rature Set point Value Set Appliance Stage Switching Differential Value Select Appliance Post Circulate Time Check Appliance Cycle Count View Last Error Encountered by Control Control the water temper...

Page 28: ...n on the display screen when the OUTLET LED is illuminated The red wires control the ECO Emergency Cutoff which shuts down the unit if the water temperature exceeds 250 F 121 C and requires a manual r...

Page 29: ...see the section labeled Procedure for Setting Stage Differential Procedure for Setting Stage Differential Once the system control and set point temperature has been entered the switching differentials...

Page 30: ...set the cycle count to zero press the ADJUST push button Press the ENTER RESET push button to successfully reset the cycle count If the ENTER push button is not pressed the reset function will not be...

Page 31: ...excessive lifting of flame from burner ports see Figure 17 If the preceding burner characteristics are not evident check for accumulation of lint or other foreign material that restricts or blocks the...

Page 32: ...rviceman should follow this procedure when the boiler s intake and exhaust piping need cleaning 1 Turn off the electrical power and manual gas shut off Allow boiler parts to cool before disassembly 2...

Page 33: ...16 red fault LED indicators to help pinpoint the source of failures In addition the display will inform the user on which stage the failure occurred by illuminating a red Stage LED In cases where the...

Page 34: ...RD STAGE 3 013 HARD STAGE 4 014 HARD LWCO 020 HARD CIRCULATE FAULT FLOW SWITCH 030 SOFT INSUFFICIENT AIR AIR PRESSURE SWITCH STAGE 1 041 SOFT STAGE 2 042 SOFT STAGE 3 043 SOFT STAGE 4 044 SOFT BLOCKED...

Page 35: ...ties including any warranty of merchantability imposed on the sale of this boiler under state law are limited to one 1 year duration for the boiler or any of its parts Some states or provinces do not...

Page 36: ...36 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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