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COPPER BOILERS FOR
HYDRONIC HEATING AND
HOT WATER SUPPLY
Instruction Manual
• Installation
GB/GW MODELS:
• Operation
1000, 1300, 1500, 1850, 2100, 2500
• Maintenance
SERIES: 400, 401, 402, 403, 404, 405
• Limited Warranty
CAUTION
TEXT PRINTED OR OUTLINED IN RED CONTAINS
INFORMATION RELATIVE TO YOUR SAFETY.
PLEASE READ THOROUGHLY BEFORE INSTALLING
AND USING THIS APPLIANCE.
WARNING: If the information in this
manual is not followed exactly, a fire or
explosion may result causing property
dama
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DIMENSIONS/CAPACITIES DATA IMPORTANT! Refer to "Installation Clearances" section of manual TOP VIEW (page 7) for recommended service clearances prior to boiler placement. LEFT SIDE FRONT VIEW REAR VIEW TABLE 1: GAS AND ELECTRICAL REQUIREMENT Manifold Pressure Electrical Characteristics MODEL 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
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DIMENSIONS DATA FOR OUTDOOR CONFIGURATION LEFT SIDE REAR VIEW FRONT VIEW TOP VIEW Figure 2. TABLE 3. DIMENSIONAL DATA AB C D E F G H J Model Inches cm Inches cm Inches cm Inches cm Inches cm Inches cm Inches cm Inches cm Inches cm GBO/GWO-1000 14 35.5 31.6 80.3 71.8 182.4 15.5 39.4 39.75 101 58.25 148 15.9 40.83 16 40.64 46.8 118.9 GBO/GWO-1300 24.75 62.9 31.6 80.3 82 208.3 15.5 39.4 39.75 101 58.25 148 15.9 40.83 16 40.64 57.3 145.5 GBO/GWO-1500 30 76.2 31.6 80.3 89 226 15.5 39.4 39.75 101 58.2
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TABLE 4: RECOVERY CAPACITIES TEMPERATURE RISE - DEGREES °F (°C) Input Rating Water 40°F 50°F 60°F 70°F 80°F 90°F 100°F 110°F 120°F 130°F MODEL BTU/Hr. (kW) Flow (22.2°) (27.7°) (33.3°) (38.8°) (44.4°) (50°) (55.5°) (61.1°) (66.7°) (72.2°) GW - 1000 990,000 (290.1) GPH 2520 2016 1680 1440 1260 1120 1008 916 840 775 LPH 9526 7620 6350 5443 4763 4234 3810 3462 3175 2930 GW - 1300 1,300,000 (380.9) GPH 3309 2647 2206 1891 1655 1471 1324 1203 1103 1018 LPH 12508 10006 8339 7148 6256 5
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GROUNDING INSTRUCTIONS At times you may not be able to smell an LP gas leak. One cause is odor fade, which is a loss of the chemical odorant that gives LP This boiler must be grounded in accordance with the National gas its distinctive smell. Another cause can be your physical Electrical Code, NFPA 70 or the Canadian Electrical Code CSA 2 condition, such as having a cold or diminishing sense of smell with C22.1 and/or local codes. The boiler is polarity sensitive, correct age. For these reaso
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DIFFERENTIAL PRESSURE SWITCH COMBUSTION AIR BLOWER The differential pressure switch ensures that a sufficient differential Provides air for combustion process. The blower settings are adjustable through the use of the air shutter, however, blowers are exists between the air pressure in the pre-mix chamber and the inlet set at the factory and might require slight adjustment depending of the burner for safe, combustion and proper low NO emission. The x on site installation. switch has two pressure
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side of the tank on a center line within the upper six (6) inches DRAIN VALVE (Not Supplied) (15 cm) of the top of the tank. The tapping shall be threaded in accordance with the latest edition of the Standard for Pipe Threads, Additional drain valves must be obtained and installed on each boiler General Purpose (inch), ANSI/ASME B1.20.1. The location of, or and tank for draining purposes. intended location for, the T & P relief valve shall be readily accessible for servicing or replacement. SA
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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. PARTICULAR CARE MUST BE TAKEN WHEN EXHAUST FANS, COMPRESSORS, AIR HANDLING EQUIPMENT, ETC., MAY INTERFERE WITH THE COMBUSTION AND VENTILATION AIR SUPPLIES OF THIS BOILER. MODEL COMBUSTIBLE BASE KIT NUMBER CHEMI
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If the confined space is within a building of tight construction, air SEE FIGURE 6). AT LEAST TYPE B VENTING MUST BE USED for combustion, ventilation, and draft hood dilution must be WITH THE STANDARD VENTING OPTION (thru-the-roof) USING obtained from outdoors. When directly communicating with the THE NATIONAL FUEL GAS CODE VENT TABLES. TYPE B VENT outdoors or communicating with the outdoors through vertical PIPE CANNOT BE USED IF THE BOILER IS VENTED ducts, two permanent openings, located in
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POWER VENT (OPTIONAL) the exhaust vent pipe must be listed for use with category III gas burning heaters such as "Saf-T-Vent" manufactured by Heat-Fab The length of vent used in horizontally vented installations can be Inc. This vent system must be 100% sealed with a condensate extended beyond the lengths shown in Tables 11 and 13 by trap located as close to the boiler as possible. When sizing exhaust implementing the kits listed below: piping and intake air piping, 90-degree elbows are equiva
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fireplace dampers and other gas burning appliances to their 7. Avoid areas where condensate drainage may cause previous conditions of use. problems such as above planters, patios, or adjacent to windows where the steam from the flue gases may cause All boiler venting systems shall be installed in accordance with fogging. the National Fuel Gas Code, ANSI Z223.1 or CAN/CSA-B149.1 (current edition), or applicable provisions of the local building 8. Select the point of wall penetration where the min
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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. Figure 6. TABLE 10. STANDARD VERTICAL VENTING (CATEGORY I) APPLIANCE CERTIFIED EXHAUST MAXIMUM LENGTH MODEL CATEGORY VENTING VENT SIZE WITHOUT BAROMETRIC DAMPER MATERIAL INCHES (cm) FEET (m) TYPE B OR 10”(25.4 cm) 35 Feet (10.7 m) without damper I I000 EQUIVALENT *70 Feet (21.3 m) max. with damper 1300 TYPE B OR
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STANDARD VENT - HORIZONTAL (CATEGORY III) Figure 7. TABLE 11. STANDARD HORIZONTAL VENTING (CATEGORY III) APPLIANCE CERTIFIED EXHAUST MAXIMUM MODEL CATEGORY VENTING VENT SIZE VENT LENGTH MATERIAL INCHES (cm) FEET (m) STAINLESS III I000 70' (21.3 m) 10”(25.4 cm) STEEL 1300 STAINLESS III 70' (21.3 m) 12" (30.5 cm) 1500 STEEL 1850 STAINLESS III 35' (10.7 m) 14"(35.6 cm) 2100 STEEL STAINLESS III 16" (40.6 cm) 35' (10.7 m) 2500 STEEL WARNING: No substitutions of flue pipe or vent cap material are a
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DIRECT VENT - VERTICAL (CATEGORY I) Figure 8. TABLE 12. DIRECT VENT (VERTICAL EXHAUST CONFIGURATIONS) APPLIANCE CERTIFIED EXHAUST VENT MAXIMUM AIR INTAKE AIR INTAKE MAXIMUM MODEL CATEGORY EXHAUST VENT SIZE EXHAUST VENT MATERIAL SIZE AIR INTAKE MATERIAL INCHES (cm) LENGTH FT (m) INCHES (cm) LENGTH FT (m) GAL. STEEL 10" TYPE B OR 35' 8" 35' I PVC, ABS OR I000 EQUIVALENT (25.4 cm) (10.7 m) (20.3 cm) (10.7 m) CPVC GAL.STEEL TYPE B OR 1300 12" 35' 10" 35' I PVC, ABS CR EQUIVALENT (30.5 cm) 1500 (10.
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DIRECT VENT - HORIZONTAL (CATEGORY III) Figure 9. TABLE 13. DIRECT VENT (HORIZONTAL EXHAUST CONFIGURATIONS) APPLIANCE CERTIFIED EXHAUST MAXIMUM AIR INTAKE AIR INTAKE MAXIMUM MODEL CATEGORY EXHAUST VENT VENT SIZE EXHAUST VENT MATERIAL SIZE AIR INTAKE MATERIAL INCHES (cm) LENGTH FT (m) INCHES (m) LENGTH FT (m) GAL. STEEL 10" STAINLESS 35' 8" 35' III PVC, ABS OR I000 (25.4 cm) (10.7 m) (20.3 cm) (10.7 m) (SEALED) CPVC GAL.STEEL 1300 STAINLESS 12" 35' 10" 35' III PVC, ABS CR (SEALED) (30.5 cm) 1500
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volume may result in condensation within the boiler on cold starts. HYDRONIC INSTALLATION This condensing of water vapor in the combustion area can be prevented if a portion of the system water flow is diverted past the The following is a brief description of the equipment required for boiler to cause an increase in boiler temperature. installations noted in Figure 10. All installations must comply with local codes. BYPASS BALANCING TABLE 14: INSTALLATION ITEMS With systems where water temperat
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This bypass may also be used with multiple boilers manifolded for Large systems with multiple boilers should include main water reverse-return flow. The system bypass would be installed from boiler temperature controls (with or without outdoor reset) to sequence the outlet to suction side of pump. boiler on and off, in relation to the load on the system. The boiler piping system of a hot water heating boiler connected to 24 VAC System Controller (Optional) heating coils located in air handling u
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related to approximate water volume of the system. The system limit the maximum tank probe temperature for GW applications. should be turned on to circulate water mix for about one hour and Failure to do this will void the warranty. If the tank probe is not then flush clean with fresh water. designated as the controlling probe, the staging of the unit will be controlled by the inlet probe and will not use the desired tank Before operating the boiler, the entire system must be filled with tempera
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ONE GENESIS (MODEL GW) HOT WATER SUPPLY BOILER WITH HORIZONTAL TANK PRESSURE RELIEF VALVE RATING SHOULD IMPORTANT NOT EXCEED PRESSURE CAPACITY OF ANY WATER FLOW SWITCH PROTECTS THE INSTALL THERMAL EXPANSION COMPONENT IN THE SYSTEM. BOILER IN CASE OF WATER SERVICE TANK ON COLD WATER INTERRUPTION OR CIRCULATOR FAILURE. SUPPLY LINE, IF CHECK VALVE PIPING SHOULD CONFORM TO LOCAL CODES. OR PRESSURE REDUCING • PIPE TO OPEN DRAIN VALVE IS USED IN SUPPLY. BALL VALVES ARE SHOWN FOR SERVICING X FACTORY-IN
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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. • PIPE TO OPEN DRAIN X FACTORY INSTALLED ON UNIT == SUPPLIED WITH UNIT = FIELD-INSTALLED DANGER TE
