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PRINTED IN U.S.A. 2526 0501

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.

PART NO. 211257-000 REV. 0

A DIVISION OF A. O. SMITH CORPORATION

EL PASO, TX., MC BEE, SC.,   RENTON, WA.,

STRATFORD-ONTARIO,  VELDHOVEN-THE NETHERLANDS

www.hotwater.com

PLACE THESE INSTRUCTIONS ADJACENT TO BOILER AND

NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.

Installation

Operation

Maintenance

Limited Warranty

Instruction Manual

GB/GW 

MODELS

:

1000, 1300, 1500, 1850, 2100, 2500

SERIES 200, 201

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.

Thank Y

ou

 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

PAGE

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
HOT WATER SUPPLY INSTALLATION ......... 17 - 19
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

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.

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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