SERVICE HANDBOOK TABLE OF CONTENTS PAGE Introduction. ........................................... 2 Installation Clearances ........................................... 3 Air Requirements .................................. 3 Contaminated Air .................................. 4 Flammable ............................................ 5 Gas Pressure ........................................ 5 Venting ................................................. 6 Location of Parts .................................
GENESIS SERVICE HANDBOOK INTRODUCTION This service handbook is designed to aid in servicing and troubleshooting A.O. Smith Genesis water heaters in the field. No duplication or reproduction of this book may be made without the express written authorization of the A.O. Smith Water Products Company. The following text and illustrations will provide you with a step-by-step procedure to verify proper installation, operation, and troubleshooting procedures.
INSTALLATION Electrical circuit boards are accessible through panels on the left end or top left of the jacket. Blowers, blower air shutters and gas valves are accessible through the upper, front panels. Burners, hot surface igniters and flame sensors are accessible through the lower, front panels. Interior Clearances to Combustibles These Genesis heaters are approved for installation on noncombustible flooring.
AIR FOR COMBUSTION DOWNDRAFT Insufficient make-up air is a major cause of combustion problems. One common example is a mechanical room where exhaust vent equipment was not considered in sizing make-up air requirements. This may result in air being pulled down the exhaust vent of the Genesis causing flue gas spillage, flame roll out, improper combustion, and/or erratic heater shut down. It can also cause the production of carbon monoxide that could result in serious personal injury or death.
AIR FOR COMBUSTION FLAMMABLE ITEM Flammable items or pressurized containers or any other potentially hazardous articles must never be placed on or adjacent to the heater. Open containers of flammable material should not be stored or used in the same room with the heater or in the area of the exterior air intake of a direct vent installation. Direct venting does not eliminate the need to remove flammable or corrosives from the area surrounding the heater.
EXTERIOR VENT CLEARANCES CATEGORY I INSTALLATION This illustrates the exterior roof clearances for Genesis unit with vertical draft venting. A gas vent shall terminate above the roof surface with a listed cap or listed roof assembly. All other gas vents shall terminate not less than 3 ft (0.6 m) above the highest point where they pass through the roof and at least 2 ft (0.6 m) higher than any portion of a building within 10 ft. (3.1 m). (NFPA 54/ANSI Z223.1) Section 7.6.2 "within 8 ft (2.
VENT TERMINATION Vent Terminations Installation Clearances Per Manufacturers Recommendations Sidewall 1. Do not exhaust over a public walkway. 2. Exhaust 6 feet horizontally from gas or electric meter and 48" below or 24" above. 3. Exhaust a minimum of 48" from any soffit or eve vent. VENTING MULTIPLE HEATERS (When installed as a Category I Appliance) For larger applications, Genesis water heaters can be commonly vented together either in a tapered manifold or constant size manifold.
MULTI-VENTING CONFIGURATIONS GENESIS 1000-2500 MODELS Horizontal Sidewall Direct Venting Rear Intake/Exhaust Vertical Direct Venting Top Exhaust Horizontal Venting With Vertical Combustion Air Intake Top Intake/Rear Exhaust Horizontal Venting With Horizontal Combustion Air Intake Rear Intake/Top Exhaust Use Barometric draft Regulator to maintain -.02 to -.04 draft if necessary.
GENESIS II VENTING GENESIS 1000-2500 MODELS The Genesis boiler may be individually vented vertically up to 35 feet without a barometric damper. Individual vents with an overall height of more than 35 feet require a barometric. Properly sized vent material and the use of a barometric damper (when required) will lead to proper vent operation. A barometric damper is required when draft exceeds -0.04 inches water column. When installed and adjusted properly, a barometric damper will maintain draft between -0.
STANDARD VENT - VERTICAL (CATEGORY I) IMPORTANT! VENT PRESURE MUST BE MAINTAINED BETWEEN -0.02" W.C. AND -0.04" W.C. AT 24" (61.0 cm) ABOVE BOILER COLLAR. STANDARD VERTICAL VENTING (CATEGORY I) MODEL APPLIANCE CATEGORY CERTIFIED VENTING MATERIAL EXHAUST VENT SIZE (INCHES) MAXIMUM LENGTH WITHOUT BAROMETRIC DAMPER (FEET) I000 I TYPE B OR EQUIVALENT 10”(25.4 cm) 35 Feet (10.7 m) without damper *70 Feet (21.3 m) max.
STANDARD VENT - HORIZONTAL (CATEGORY III) MODEL APPLIANCE CATEGORY CERTIFIED VENTING MATERIAL EXHAUST VENT SIZE (INCHES) MAXIMUM VENT LENGTH (FEET) I000 III STAINLESS STEEL AL 29-4C 10”(25.4 cm) 70' (21.3 m) 1300 1500 III STAINLESS STEEL AL 29-4C 12" (30.5 cm) 70' (21.3 m) 1850 2100 III STAINLESS STEEL AL 29-4C 14"(35.6 cm) 40' (21.3 m) 2500 III STAINLESS STEEL AL 29-4C 16" (40.6 cm) 40' (21.3 m) WARNING: No substitutions of flue pipe or vent cap material are allowed.
DIRECT VENT - VERTICAL (CATEGORY I) DIRECT VENT (VERTICAL EXHAUST CONFIGURATIONS) MODEL APPLIANCE CERTIFIED EXHAUST VENT MAXIMUM CATEGORY EXHAUST VENT SIZE EXHAUST VENT MATERIAL (IN) LENGTH (FT) I000 I 1300 1500 I 1850 I 2100 I 2500 I TYPE B OR EQUIVALENT TYPE B OR EQUIVALENT TYPE B OR EQUIVALENT TYPE B OR EQUIVALENT TYPE B OR EQUIVALENT AIR INTAKE MATERIAL AIR INLET MAXIMUM SIZE AIR INTAKE (IN) LENGTH (FT) 10" (25.4 cm) 35' (10.7 m) GAL. STEEL PVC, ABS OR CPVC 8" (20.3 cm) 35' (10.
DIRECT VENT - HORIZONTAL (CATEGORY III) TABLE 10. DIRECT VENT (HORIZONTAL EXHAUST CONFIGURATIONS) MODEL APPLIANCE CERTIFIED CATEGORY EXHAUST VENT MATERIAL I000 1300 1500 1850 2100 2500 III III III III III AL29-4C STAINLESS (SEALED) AL29-4C STAINLESS (SEALED) AL29-4C STAINLESS (SEALED) AL29-4C STAINLESS (SEALED) AL29-4C STAINLESS (SEALED) VENT SIZE MAXIMUM VENT LENGTH (INCHES) (FEET) AIR INTAKE MATERIAL AIR INLET SIZE (INCHES) MAXIMUM AIR INTAKE LENGTH (FEET) 8" 35' (10.7 m) GAL.
EXTENDED SIDEWALL VENTING (POWER ASSIST) Extended Horizontal Sidewall Venting Model # Vent Outlet Vent Pipe Size (Inch) Size (Inch) Max.
GENESIS POWER VENT WIRING DIAGRAM Electrical power to the power venter must be supplied by the installer and wired according to the Wiring Diagram. Wiring must comply with the wiring diagram in order for the boiler to function properly. The wiring is part of the boiler's safety circuit and shuts off the boiler if the Fan Proving Switch at the power venter is not made. The Genesis II Control System is also set to shut off the power venter when there is no "call for heat".
LOCATION OF PARTS Back of Heater Rear or Top Vent Connection 120V 24V Junction Box Rear Air Intake Pump Ground Terminal 1 Green Pump Neutral Terminal 2 White Pump 120VAC Hot Terminal 3 Black Ground Input Terminal 4 Green 120VAC Neutral Input Terminal 5 White 120VAC Hot Input Terminal 6 Black Tank Probe Terminal 1 Yellow Tank Probe Terminal 2 Yellow Ext. TSTAT Terminal 3 Blue Black Ext.
LOCATION OF PARTS Open Electrical Access Door Stage 1 ICB Stage 2 ICB Fuses F1,F2, F3 Stage 3 ICB Pump Relay Central Control Board (CCB) - on bottom of cabinet TB2 TB1 Manual Gas Shutoff TB3 On/Off Switch Electrical Access Door Flow Switch Press Relief Valve GW-125 PSI GB-50 PSI Water Outlet Torque Bolts to 15 lbs.
LOCATION OF PARTS Low Gas Pressure Switch closes at 5.0 ± .4 " W.C. positive pressure Set Air Shutter to 1.6"W.C. Robert Shaw DERHC-7000 White Rogers 36c68 Fasco 7082-6433 Blower Blower Prover Differential Pressure Switch HSI Flame Sensor Blower Prover Connects to Back Port of Switch (negative pressure) Blower Prover Connects to Front Port of Switch (positive pressure) Blower Air Draft Diffuser Plate Rear Hose Connects to Rear Port of Switch and Main Burner (negative pressure) A. O.
LOCATION OF PARTS Combustion Air Intake Blocked Flue Switch Located Behind Blower - Left of Exhaust Vent .60± .05"W.C. Open Flue Fasco Air Shutter Set to 1.2" W.C. on Back Hose Front Hose Positive Press Rear Hose (negative pressure) Teed Into Rear Hose of Blower Prover Switch to Set Air Shutter Blower Prover (Differential) Pressure Switch A. O.
CN12 CN6 CN1 CN8 CN5 CN14 CN2 CN7 CN11 CN3 Green 5A Red CENTRAL CONTROL BOARD (CCB) CN4 CN13 CN15 JUNCTION BOX Gas Board to Board Gas Valves Flame Sensor IGNITION CONTROL BOARD (ICB) To Next ICB From Previous Stage ICB (To and from connections are interchangable) J26 Hot Surface Ignitor (HSI) J27 Combustion Blower J24 24 VAC Transformer Line A. O.
GENESIS WIRING DIAGRAM ELECTRICAL CONNECTION DIAGRAM - 1 of 4 L 1 HOT 120 VAC 60 HZ L 2 NEUT. INPUT L 3 GND. 30 AMP C.B.
ELECTRICAL CONNECTION DIAGRAM - 2 of 4 L 1 HOT L 2 NEUT. L1 IN CN7-1 CCB G CN7-2 L2 IN LED IN 0 LED CN12-1 RELAY K1 PUMP CN12-4 CN12-3 K5 K4 RELAY* K2 IRI G.V. CN12-5 TB4-6 IRI * BLEED VALVE IRI * GAS VALVE IRI * GAS VALVE TB7 PRIMARY 120 VAC + - CONTROL BOX TRANSFORMER T1 + _ SECONDARY 24 VAC TB5 TB5 CCB 24VAC IN CN8-4 CN8-3 R 24VAC NEUT.
ELECTRICAL CONNECTION DIAGRAM - 3 of 4 T. FRONT PANEL DISPLAY BOARD CCB CN4 CN1 24V AC TB3-34 CN13-6 LOW GAS SW. TB3-35 CN1-1 TB1-3 OUTLET WATER PROBE 0-5V DC CN1-2 TB1-4 CN1-3 TB1-5 INLET WATER PROBE 0-5V DC CN1-4 TB1-6 24V AC TB1-8 WATER FLOW SW CN13-7 TB1-7 24V AC BLOWER #1 PROVER SW. TB2-14 CN14-5 TB2-15 24V AC BLOWER #2 PROVER SW. TB2-16 CN14-6 TB2-17 24V AC BLOWER #3 PROVER SW. TB2-18 CN14-7 TB2-19 24V AC BLOWER #4 PROVER SW.
ELECTRICAL CONNECTION DIAGRAM - 4 of 4 24VAC HOT CN11-5 LOW WATER CUT-OFF & SW.* TB1-11 24VAC NEUT. CN11-6 TB1-10 CN13-8 CCB TB1-9 24V AC TB3-36 IRI GAS VALVE PROVER SW.* CN13-9 TB3-37 CN3-3 EXT 24 D-BOX-4 EXTERNAL THERMOSTAT* CN3-1 K2 CN11-3 EXT 24 D-BOX-3 EXT 24 D-BOX-7 24VAC HOT 24VAC NEUT. CN11-4 CN14-4 24V AC EXT 24 D-BOX-5 TB3-26 CN13-2 24V AC HIGH GAS SW. #1* TB3-27 TB3-28 CN13-3 24V AC POWER VENT CONTROL & PROVER SW.* EXT 24 D-BOX-6 HIGH GAS SW.
WATER PIPING This manual will discuss using a Genesis GW (water heater) model installed for potable hot water. A separate manual will discuss installation of GB (Boiler) models for hydronic heating applications. Proper flow rates through the Genesis will result in a 25-40° F temperature rise inlet to outlet. Available circulators base sizing on the use of 75 equivalent feet of piping between the storage tank and Genesis.
GENESIS PUMPS STANDARD FLOW PUMPS STANDARD PUMPS - GW MODELS ONLY MODEL IMPELLER BOILER (OR EQUIV.) DIAMETER HP GW1000-1500 TACO 1635-S21 4.7" 1/2 GW1800-2500 TACO 1635-S22 5.8" 1 ELECTRIC 7.0/3.5A 13.4/7.9 A PRESSURE DROP INCLUDES THE LOSS THROUGH 50 (15.2M) EQUIVALENT FEET OF PIPE AND NORMAL FITTINGS, WHEN INSTALLED WITH STORAGE TANK. Genesis BTU Input/Output And Flow Rates BTU Input/Output Boiler Rate of Flow and Pressure Drop 20 Deg.F Rise Model # GW -1000 Input Rating Output Rating BTU/Hr.
GENESIS 1000-2500 MODELS A. O.
CENTRAL CONTROL BOARD 1 PER BOILER (Inside, Bottom of Cabinet) To Stage 1 ICB To Remote Display (OPT) Dip Switches To Display Board SW1 A B C D E F G H TABLE - CONFIGURATION OF OFF ON 3 Stage 4 Stage 3 Trials 1 Trial No IRI gas valve IRI gas valve Inlet Tank No external TSTAT External TSTAT Outlet 210° F Outlet 240° F 190° F 220° F Degrees F Degrees C A. O.
IGNITION CONTROL BOARD 1 PER STAGE (Inside, Around Walls of Cabinet) Gas Valve 1 Board per stage (3 or 4) Board to Board Gas Valve Power To Next Stage ICB Flame Sensor From Previous Stage ICB (To and from connections are interchangable) J26 J27 Hot Surface Ignitor (HSI) Combustion Blower J24 24 VAC Transformer Line Voltage Each ICB is responsible for a: • combustion blower • hot surface igniter • gas valve Each ICB will monitor: • a gas valve • gas valve relay • flame sense • igniter current Each
GENESIS 1000-2500 MODEL'S CONTROL SYSTEMS SPECIFICATIONS 1 PER BOILER Red Red System Display Board L ED D i sp l a y 4 -d i g i t , 7 -s e g m e n t L E D d i s p l a y T e m p e r a t u r e d i s p l a y f o r ° F o r ° C D i s c re t e L E D s 2 5 L E D s f o r s t a t u s / d i a g n o s t i cs St a g e L ED s 4 R e d , 4 G re e n D i a g n o st i c L ED s 1 2 R ed ECO Failure Probe Failure Environmental: Flame Failure Igniter Failure Operating Temperature Insufficient Air Range -40°F (-40°C) to 185°F
SEQUENCE OF OPERATION 3 STAGE MODELS - TEMPERATURE/STAGE LADDER EXAMPLE Condition: Central control Board (CCB) dip switch settings: SW1-A Set to "Off" (3 Stage) SW1-C-Set to "Off" (no IRI gas valve in use) SW1-E-Set to "On" (external thermostat in use) All other switches either "On" or "Off" CONFIGURATION SWITCH TABLE CCB Responsibility: SW1 OFF ON SELECTION: A 3 Stage 4 Stage Either 3 or 4 stage system Staging ICB's B 3 Trials 1 Trial Either 3 or 1 trial(s) for ignition Monitor Safety Limit Devices C No IR
SHUT DOWN SEQUENCE 3-STAGE MODELS Stage 3 - Set Point is Reached Post Purge Set Time Post SetBlower Time Blower Blower Post Purge Purge (25 seconds) (25 seconds) ( 25 sec onds rec ommended) Stage 3 – Gas Valv e De-energized Stage 2 -Set Point Reached Stage 2 -Gas Valv e De-energized Stage 2 Blower (if equipped) Post Purge Stage 1 - Set Point Reached Stage 1-Gas Valv e De-energized Blower Post Purge Set Time Blower, Post Purge ( 25 sec onds rec ommended) (25 seconds) All Blower Post Purge Completed
ELECTRICAL INFORMATION CENTRAL CONTROL BOARD SUPPLY CIRCUIT BOARD Probe#1 Probe #2 P robe #3 or (Opt ) 120 VAC; 60 Hz 18-30 VAC, 60 Hz TEMP SENSING TYPE SENSOR CONNECTS TO RECEPTACLES Outlet water Thermistor CCB CN 1 High Limit 24 VDC-NC CCB CN 14 Inlet water Thermistor CCB CN1 Therm is t or CCB CN2 Remote tank Temp. probe Rem ot e t ank t herm os t at 24 V A C SWITCHES - ALL ARE 24VAC STATISTICS INCH W.C. P o w e r V e n t S w i t c h (O P T ) N. O . Differential Blower Prover N.O. .70 ± .
ELECTRICAL Input Power: Supply Line Circuit Board Input Specifications: Flame Sense Safet y Limit Output Specifications: High Speed Combustion Blower Low Speed Combusion blower Hot Surface Ignit er Gas Valve Igniter current Proving: Norton Model 271Y; Igition Timing: Pre-purge (Combusion Blower) Igniter Proving Igniter Activation Period Trial For Ignition Period Flame Establishing Period Flame Failure Response Time Int er-Purge Post -purge Communications: Board t o Board Environmental: Operating Temperature
SETTING SYSTEM CONFIGURATION SWITCHES AND JUMPERS CENTRAL CONTROL BOARD (CCB) CONFIGURATION Dip Switches Table - Configuration SW1 Off On A 3 Stage 4 Stage B 3 Trials 1 Trial C No IRI Gas Valve IRI Gas Valve D Inlet Tank E No External TSTAT External TSTAT F Outlet 210°F Outlet 240°F G 190°F 220°F H Degrees F Degrees C *IRI- Industrial Risk Insurance A. O.
CONFIGURATION JUMPERS ON IGNITION CONTROL BOARD (ICB) NOTES: 1. Connections CN15 and CN16 are electrically the same -- item cable 2 can be connected to either. 2. Connections CN11 and CN12 are electrically the same -- item 1 cable can be connected to either.
CENTRAL CONTROL CIRCUIT BOARD CONNECTIONS These connect to Terminal Board strips on the drop down panel - See page 17`.
CENTRAL CONTROL CIRCUIT BOARD CONNECTIONS CN12 CN6 CN5 CN1 CN2 CN8 CN7 CN14 CN3 Green LED 5A Fuse CN4 Red Light CN11 CN13 CN15 A. O.
IGNITION CONTROL CIRCUIT BOARD CONNECTIONS CN1 - Line Voltage pin 1 = L1 (120 VAC) pin 2 = Nuetral pin 3 = GND - Green CN12 - CCB to ICB Serial Communications Cable pin 1 = Not used pin 2 = GND pin 3 = RXD pin 4 = TXD pin 5 = GRD pin 6 = Not used CN17 - Combustion Blower pin 1 = 120 VAC output - Black pin 2 = Neutral - White pin 3 = GND - Green CN4 - Transformer pin 1 = L1 (no connection necessary) pin 2 = Neutral (no connection necessary) pin 3 = Ground White/Black pin 4 = 24 VAC Black/White CN5 - 120 VA
IGNITION CONTROL CIRCUIT BOARD CONNECTIONS CN15 CN16 CN13 CN15 CN11 CN12 Green Light J26 J27 CN5 J24 CN17 CN4 CN1 A. O.
CENTRAL CONTROL BOARD FRONT PANEL DISPLAY BOARD CCB CN4 CN1 24V AC TB3-34 CN13-6 LOW GAS SW. Closes at 5.0 ± .4" W.C. TB3-35 Black CN1-1 Thermistor TB1-3 OUTLET WATER PROBE CN1-2 Opens at 210° or 240° per CCB Dip Switch "F" 0-5V DC Black TB1-4 Blue CN1-3 Thermistor TB1-5 Adjustable 80°-190°F or 220° per CCB Dip Switch "G: sets stage set point if: No external control is used or a 24 Vac tank control is used.
CENTRAL CONTROL BOARD 24VAC HOT CN11-5 24VAC NEUT. CN11-6 TB1-11 CN13-8 CCB TB1-9 24V AC TB3-36 CN13-9 EXT 24 D-BOX-4 24V CN3-1 CN11-3 IRI GAS VALVE PROVER SW* TB3-37 CN3-3 K2 CN11-4 CN14-4 Adjustable at tank (typically 100 185° F). If used , stage settings are controlled at the inlet probe. EXTERNAL THERMOSTAT* EXT 24 D-BOX-3 EXT 24 D-BOX-7 POWER VENT CONTROL & PROVER SW* 24VAC HOT 24VAC NEUT. Opens if water is below the cut off sensor - CSD1 and IRI equipped boilers.
SYSTEM DISPLAY BOARD Yellow LEDs Green LEDs Red LEDs Display will indicate inlet or tank temperature (depending on Dip Switch SW1-D) Genesis must be operated after 1 complete cycle with the new settings to "lock" them into memory To Display/Change Inlet or Tank Set Points To Display/Change Inlet or Tank Set Points Select Push Select Set Point "On" Inlet LED "On" Adjust Stage Set Point Differential – “ON” Stage 1 “ON” Hold in button and release to increase or decrease setting Push Adjust Push
SYSTEM DISPLAY BOARD - continued Display will indicate inlet or tank temperature (depending on Dip Switch SW1-D) Genesis must be operated with the new settings to "lock" them into memory Post-Circulate Time 45, 90 180 seconds or continuous 45 seconds recommended.
FAULT CONDITIONS CATEGORIZED BY BOILER TERMS: Soft Lockout: Can be reset by pressing the Enter/Reset push button on the control display. If this push button is NOT pressed, the control will re-initiate an ignition process )provided the call-for-heat is still present) after (1) one hour. This process will continue hourly as long as there is a call-for-heat. Error Codes between 030 and 070 are "Soft Lockouts". Hard Lockout: Requires a manual reset. Push the Enter/Reset push button on the control display.
FAULT CONDITIONS CATEGORIZED BY BOILER CALL-FOR-HEAT/PRE-CIRCULATE STATE Limit String Fault: During call-for-heat/pre-circulate, if the Control senses a limit string fault, the Control will wait 60 seconds (nominal) for the fault to clear. If after 60 seconds the Control still senses a limit string fault, the Control will determine the exact fault condition, and then enter the lockout mode. The appropriate LED will illuminate and an error code is displayed. If applicable, a Red stage LED will illuminate.
FAULT CONDITIONS CATEGORIZED BY BOILER corresponding to the stage in which the failure occurred. A red stage LED, corresponding to the stage in which the failure occurred, will also illuminate. The appropriate LED(s) will remain illuminated until manual reset. Temperature Probe Fault: If the control detects an open or shorted temperature sensor in the controlling temperature probe, or in the Appliance Max. Temperature Probe (Outlet Probe), the control will enter the lockout mode.
FAULT CONDITIONS CATEGORIZED BY BOILER flame failure fault condition is written to nonvolatile memory within 4 seconds. The red Flame Failure LED will illuminate and the display will show an error code corresponding to the stage on which the failure occurred. The appropriate Red stage LED will also illuminate. The appropriate LED(s) will remain illuminated until manual reset.
TROUBLESHOOTING ERROR CODES Soft Lockout: Can be reset by pressing the Enter/Reset push button on the control display. If this push button is NOT pressed, the control will re-initiate an ignition process (provided the callfor-heat is still present) after (1) hour. This process will continue hourly as long as there is a callfor-heat. Error Codes between 030 and 070 are "Soft Lockouts" All codes NOT between 030 and 070 are "Hard Lockouts". Hard Lockout: Requires a manual reset.
TROUBLESHOOTING ERROR CODES Error Code "010" Display - High Limit LED "On" Display will show "LOCO 010" Power is "ON" - Plugs are in receptacles ECO/OUTLET TEMP Central Control Board Red Red Black CN6 CN1 Black CN5 CN14 CN2 Terminal Board #1 4 3 2 12 6 1 7 1 Red Red Black Black Red Wires are to High Limit ECO (24VDC) Black wires are to Temperature Probes (Thermistor) < 5VDC A. O.
TROUBLESHOOTING ERROR CODES Error Code "01" Stage 1, 2, 3, or 4 - No Gas Valve Power On Display Board red light is on "Gas Valve Fail" Red indicates Stage LED - On Display Window will show "LOCO - 01?" The Stage Gas Valve did not receive power to open. Power is "ON" - Plugs are in receptacles Ignition Control Board "01?" indicates No Gas Valve Power Sensed - The last number in the code is the Stage Ex.
TROUBLESHOOTING ERROR CODES Error Code "020" - Additional Control to Meet CSD-1 or IRI Code Requirements - A Low Water Cut Off Switch On Display Board red light is on "LWCO Fail*" Display Window will show "LOCO 020". Red indicates LED - On Power is "ON" - Plugs are in receptacles Central Control Board Terminal Board 1 "020" indicates Low Water Cut Off - OPTIONAL CSD1/STANDARD IRI MODELS Lockout If error code is … Status … then check water level - fill as needed.
TROUBLESHOOTING ERROR CODES Error Code "030" - This indicates that the Flow Switch is not closed. On Display Board red light is on "Circulation Fail" Display Window will show "LOCO 030". Red indicates LED - On Power is "ON" - Plugs are in receptacles Central Control Board "030" indicates Circulate Fault (Flow Switch) Lockout Status Soft If error code is … 030 … then check connection and 24V hot from CCB CN13, Pin 1 to TB3, Terminal 25.
TROUBLESHOOTING ERROR CODES Error Code "04" Stage 1, 2, 3, or 4 - Indicates Insufficient Air (Air Pressure Switch) On Display Board red light is on "Insufficient Air" Red LED for indicated Stage - On "Insufficient Air" relates to pressure at the Blower Prover (Differential) Switch Display Window will show "LOCO 04?". Power is "ON" - Plugs are in receptacles "04?" indicates Insufficient Air (Air Pressure Switch). Blower prover switch open. Closes at .70 W.C. differential positive pressure.
TROUBLESHOOTING ERROR CODES Error Code "060" - This indicates Blocked Flue On Display Board red light is on "Blocked Flue" Display Window will show "LOCO 060". Red indicates LED - On Blocked Flue Switch has opened (.60 + pressure to open). Switch is located to the left of the vent and rear of the cabinet - near air intake opening. Power is "ON" - Plugs are in receptacles Central Control Board CN 14 Terminal Board 2 "060" indicates Insufficient Blocked Flue.
TROUBLESHOOTING ERROR CODES Error Code "070" Stage - Indicates Power Vent Problem On Display Board red light is on "Power Vent Fail*" Display Window will show "LOCO 070". Only if an optional Power Venter has been installed in the exhaust vent. Power Venter may or may not have been purchased from A.O. Smith. Power Venter Relay would connect to external 24V Junction Box, Terminal 5, 6 and 7.
TROUBLESHOOTING ERROR CODES Error Code "08" Stage 1, 2, 3, or 4 - This indicates Igniter Failure On Display Board red light is on "Ignitor Fail" Display Window will show "LOCO 08". Red LED for indicated Stage - On This is an electrical feedback from the HSI. Power is "ON" - Plugs are in receptacles Terminal Boards (strips) located inside bottom of Control Box Ignition Control Board "08?" indicates Igniter Failure. The last number in the code is the Stage (Ex.
TROUBLESHOOTING ERROR CODES Error Code "090" - Indicates Low Gas Failure On Display Board red light is on "Low Gas Fail" Display Window will show "LOCO 090" Power is "ON" - Plugs are in receptacles "090" indicates Low Gas Failure Lockout If error code is … Status Hard 090 … then opens at 5.0 ± .04" W.C. or less.
TROUBLESHOOTING ERROR CODES Error Code "10" Stage 1, 2, 3 or 4 - Only Applicable to CSD-1 and IRI Equipped Models Display Board Red "High Gas Fail" LED is ON. Display window will show "LOCO 10 __" Red LED for Stage is ON. Power ON - Plugs in receptacles High Gas Pressure Switch (one per stage) opens at 5.25" W.C. pressure (12.8" W.C. - Prop) Manifold Pressure "10?" indicates Excess Manifold Gas Pressure. The last number of the code is the stage (Ex.
TROUBLESHOOTING ERROR CODES Error Code "11" Stage 1, 2, 3 or 4 - Gas Valve Relay Failure • • • • Display Board Red "Gas Valve Fail" LED is ON. Display window will show "LOCO 11 __" Red LED for Stage is ON. Power ON - Plugs in receptacles CN15 Board to Board Gas CN16 "11?" indicates Gas Valve Relay Failed. Lockout Status Hard The last number of the code is the stage (Ex. 0111 = Stage 1) If error code is … Stage 1 111 Stage 2 112 Stage 3 Stage 4 113 114 A. O.
TROUBLESHOOTING ERROR CODES Error Code "12" Stage 1, 2, 3 or 4 - This Indicates A Flame Failure • • • • • Display Board Red "Flame Fail" LED is ON. Display window will show "LOCO 12 __" Red LED for Stage is ON. Power ON - Plugs in receptacle Indicates that flame was sensed but then lost. ICB for Stage CN6 Flame Sensor Lower Part of Heater "12?" indicates That Flame Was Sensed But Then Lost. The last number of the code is the stage (Ex.
TROUBLESHOOTING ERROR CODES Error Code "131, 132, 133" - Temperature Probe Faults • Display Board Red "Temp. Probe Fail" LED is ON. • Display window will show "LOCO 13 __" - Third digit indicates which probe is not being sensed. • Outlet probe connects to CCB CN1 Pins 1 and 2 • Inlet probe connects to CCB CN1 Pins 3 and 4. • Tank temperature probe connects to CCB CN 2 Pins 1 and 2. ECO Outlet Outlet ECO "131, 132, 133" indicates Temperature Probe Faults.
TROUBLESHOOTING ERROR CODES Error Code "140" - Industrial Risk Insurance Gas Valve Failure IRI Controls are an option on these heaters. • Display Board Red "Gas Valve Fail" LED is ON. • Display window will show "LOCO 140" • "0" in the 3rd position indicates that the Central Control Board is noting-not ICB- A voltage confirmation through the IRI Gas Valve Prover Switch.
TROUBLESHOOTING ERROR CODES Error Code "210" - Indicates Central Processing Unit (CPU) Fault • Display window will show "LOCO 210" The CPU, located on the Central Control Board, has a non-repairable fault. Replace the CCB. Miscellaneous Information 1. These units require a proper hot (voltage supply), "clean" neutral and proper grounding to operate correctly, to minimize the risk of electrical problems, it is recommended that wiring to this appliance be isolated from wiring to other appliances. 2.
GENESIS START-UP INSTRUCTIONS MODELS GB/GW/GBO/GWO 1000 - 2500 SERIES 200 AND 201 Page 1 of 2 GENERAL INFORMATION This is the approved factory start-up procedure and certificate for an A.O. Smith GB/GW/GBO /GWO model 1000 - 2500, series 200 & 201 boiler. IMPORTANT It is the owner’s responsibility to request a factory start-up. The Genesis unit(s) must be fully installed prior to start-up.
START-UP INSTRUCTIONS FOR GENESIS MODELS GB, GW, GBO AND GWO, SERIES 200 AND 201 Page 2 of 2 Blower and Air Shutter Setting and Adjustment Note: The blowers are factory pre-set and shouldn’t require adjustment. The Genesis II units are equipped with multiple blowers; 2 blowers are used on 3-stage units and 3 blowers are used on 4-stage units. All blowers must be running while balancing.
TABLES Gas GAS VALVES Model Vendor Natural Propane Natural White Rogers 36C 68-820 White Rogers 2000 DERHC 5N2 Robert Shaw 7000 DERHC Electric Comments 24V; 60 Hz; .6A Coil 180Ohms 24V; 60 Hz; .6A Coil 180Ohms 3/4" x 3/4"; 3.5" W.C. 3/4" x 3/4"; 10.0" W.C. 24VAC; .7A Coil - 70 Ohms 1" x 1"; 3.5" W.C. Propane Robert Shaw 7000 DERHC-LP 24VAC; .7A Coil - 70 Ohms 1" x 1"; 10.0" W.C. Note: White Rogers Gas Valves are assoicated with 3 burner manifolds.
A. O.
A. O.
A. O.
A. O.
A. O.
A. O.
A. O.
