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COPPER BOILERS FOR
HYDRONIC HEATING AND
HOT WATER SUPPLY
• Installation
Instruction Manual
• Operation
GB/GW MODELS:
• Maintenance
1000, 1300, 1500, 1850, 2100, 2500
SERIES 200, 201
• 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
for buying this cost
da
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ROUGH-IN DIMENSIONS 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 CHARACTERISTICS 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 Pressure: 14.0 In. W.C.
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TABLE 3: RECOVERY CAPACITIES Temperature Rise - Degrees °F (°C) Input Rating Gal/Liter 40°F 50°F 60°F 70°F 80°F 90°F 100°F 110°F 120°F 130°F MODEL BTU/Hr. (kW) per Hr. (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) 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 12508 10006 8339 7148 6256 5560 5005 4547 4169 3848 GPH 3309 2647 2206 1891 1655 1471 1324
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PRECAUTIONS FOREWORD IF THE UNIT IS EXPOSED TO THE FOLLOWING, DO NOT These designs comply with the latest edition of the American OPERATE UNTIL ALL CORRECTIVE STEPS HAVE BEEN MADE National Standards for Gas-Fired, Low-Pressure Steam and Hot BY A QUALIFIED SERVICEMAN: Water Boilers, ANSI Z21.13 and CGA 4.9/CGA 3.3 latest edition, as a low pressure boiler. 1. EXPOSURE TO FIRE. 2. IF DAMAGED. Detailed installation diagrams are found in this manual. These 3. FIRING WITHOUT WATER. diagrams will serv
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Example: A Genesis boiler is rated at 1,300,000 Btu/hr. input at sea FLAME SENSOR level. At an altitude of 5,000 (1500m), the prejet orifices will decrease the input rate by 20% (= 4% x 5) to a new rating of 1,040,000 Btu/hr. The flame sensor acts to prove the flame has carried over from the (= 80% x 1,300,000 Btu/hr.) The input reduction is achieved by the ignitor to the right-most burner. If no flame is sensed, the gas prejet orifices through self-regulation. valve(s) will close automatical
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probe is not supplied with the GB models. A tank probe can be If any safety relief valve is replaced, the replacement valve must used as an option to control loop temperature and unit staging. comply with the latest version of the ASME Boiler and Pressure Additionally, the Inlet Temperature Probe can be used as the loop Vessel Code, Section IV (HEATING BOILERS). Select a relief valve thermostat in some heating (GB) applications. These types of with a discharge rating NOT less than the boiler
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• THE BOILER MUST NOT BE INSTALLED ON CARPETING. INSTALLATION CLEARANCES • THE BOILER SHOULD NOT BE LOCATED IN AN AREA WHERE Sufficient area should be provided at the front and sides of the IT WILL BE SUBJECT TO FREEZING. unit for proper servicing. For ease of service, minimum • THE BOILER SHOULD BE LOCATED NEAR A FLOOR DRAIN. clearances of 24" (61.0 cm) in the front and 18" (46.0 cm) on • THE BOILER SHOULD BE LOCATED IN AN AREA WHERE the sides are recommended. It is important that the minimu
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PROVIDED FOR PROPER COMBUSTION AND VENTILATION IN sufficient openings for air must be provided in the walls. ACCORDANCE WITH THE NATIONAL FUEL GAS CODE, ANSI UNDERSIZED OPENINGS WILL CAUSE AIR TO BE DRAWN INTO Z223.1 OR CAN/CSA-B149.1 AND .2 (LATEST EDITIONS) OR THE ROOM THROUGH THE CHIMNEY, CAUSING POOR APPLICABLE PROVISIONS OF THE LOCAL BUILDING CODES. COMBUSTION. SOOTING MAY RESULT WITH AN INCREASED AN INSUFFICIENT SUPPLY OF AIR MAY RESULT IN A YELLOW, RISK OF ASPHYXIATION. LUMINOUS BURNER F
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LOCATION REQUIREMENTS (INTAKE/EXHAUST) 1. Seal any unused opening in the common venting system. 2. Visually inspect the venting system for proper size and horizontal Intake/Exhaust Installation Requirements (See figure 4): pitch and determine there is no blockage or restriction, leakage, corrosion or other unsafe condition. 1. The termination must be 12 inches (30.5 cm) above snow or 3. Isolate the space containing the appliance(s) remaining grade level whichever is higher. connected to the comm
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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 5. TABLE 7. STANDARD VERTICAL VENTING (CATEGORY I) APPLIANCE CERTIFIED EXHAUST MAXIMUM LENGTH WITHOUT MODEL CATEGORY VENTING VENT SIZE BAROMETRIC DAMPER (FEET) MATERIAL (INCHES) 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 35 Feet (10.7 m) without damper I
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STANDARD VENT - HORIZONTAL (CATEGORY III) Figure 6. TABLE 8. STANDARD HORIZONTAL VENTING (CATEGORY III) APPLIANCE CERTIFIED EXHAUST MAXIMUM MODEL CATEGORY VENTING VENT SIZE VENT LENGTH MATERIAL (INCHES) (FEET) 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 14"(35.6 cm) 70' (21.3 m) 2100 STEEL STAINLESS III 16" (40.6 cm) 2500 70' (21.3 m) STEEL WARNING: No substitutions of flue pipe or vent cap material are allowed
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DIRECT VENT - VERTICAL (CATEGORY I) Figure 7. TABLE 9. DIRECT VENT (VERTICAL EXHAUST CONFIGURATIONS) APPLIANCE CERTIFIED EXHAUST VENT MAXIMUM AIR INTAKE AIR INLET MAXIMUM MODEL CATEGORY EXHAUST VENT SIZE (INCHES) EXHAUST VENT MATERIAL SIZE (INCHES) AIR INTAKE MATERIAL LENGTH (FEET) LENGTH (FEET) 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 (10.7 m) (25
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DIRECT VENT - HORIZONTAL (CATEGORY III) Figure 8. TABLE 10. DIRECT VENT (HORIZONTAL EXHAUST CONFIGURATIONS) APPLIANCE CERTIFIED VENT MAXIMUM AIR INTAKE AIR INLET MAXIMUM MODEL CATEGORY EXHAUST VENT SIZE VENT LENGTH MATERIAL SIZE AIR INTAKE MATERIAL (INCHES) (FEET) (INCHES) LENGTH (FEET) 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 (10.7 m) (25.4 cm) (1
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STANDARD (VERTICAL) VENTING, CATEGORY I STANDARD (HORIZONTAL) VENTING, CATEGORY III Vent sizing, installation and termination shall be in accordance THIS BOILER MAY BE VENTED ACCORDING TO TABLE 7 (ALSO with the NATIONAL FUEL GAS CODE, ANSI Z223.1 OR SEE FIGURE 5). AT LEAST TYPE B VENTING MUST BE USED CAN/CSA-B149.1 AND .2 (LATEST EDITIONS). If applicable, all WITH THE STANDARD VENTING OPTION (thru-the-roof) USING local, utility, state/provincial regulations on venting must be followed. THE NAT
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CONVENTIONAL SPACE HEATING INSTALLATION SYSTEM INSTALLATION Modern fin type boilers are exceptionally fast heating units. The low GENERAL water volumes in relation to firing rates require special attention to water flow rates for smooth, efficient operation. These If the system is to be filled with water for testing or other purposes considerations for the A. O. Smith copper heat exchanger boilers during cold weather and before actual operation, care must be are covered below. taken to prevent
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The circuits should be spaced on the header at a minimum of installation might be controlled directly from space temperature 3" (7.6 cm) center to center. Install a balancing cock in each return thermostat(s). Multiple boiler installations are more effective when line. the boilers are sequenced in and out of operation by some form of main water temperature controller. With one or two boilers, individual Manifold headers are recommended for split systems with or control settings at progressive
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mandatory but offers smooth, efficient operation of a modern HARD WATER CONDITIONS system. Where hard water conditions exist, water softening or the threshold Normal use of flow control valves is required to prevent cross type of water treatment is recommended. This will protect the circulation of zones as with any multiple pump system. dishwashers, coffee urns, water heaters, water piping and other equipment. When water softening or water treatment is not practical, Large systems with multipl
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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 SAFETY 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-I
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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 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 DANGER T
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Table 13. Suggested Pipe Size For Multiple Gas Appliances (Natural) Maximum Capacity of Pipe in BTU/hr and kW for Gas Pressures of 14 in. W.C. (0.5 psi) or Less and a Pressure Drop of 0.5 in. W.C. 3 (based on 0.60 Specific Gravity Gas w/Heating Value of 1,000 BTU’s/Ft ) Nominal Length of Pipe in Feet (Metres) 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 Ft. 200 Ft. (Inches) (3.05) (6.10) (9.14) (12.19) (15.24) (18.29) (21.34) (24
