AO Smith Water Heater 400 Series User Manual

GAS-FIRED COMMERCIAL

REPLACEMENT PARTS LIST

COPPER BOILERS FOR HYDRONIC

HEATING & HOT WATER SUPPLY

MODELS GB/GW: 1000, 1300,

1500, 1850, 2100, 2500

SERIES: 400 - 405

A.O. SMITH WATER PRODUCTS COMPANY

500 TENNESSEE WALTZ PARKWAY, ASHLAND CITY, TN 37015

Phone: 1-800-433-2545 • Fax: 1-800-433-2515

website: www.hotwater.com/parts • email: [email protected]

PRINTED IN U.S.A. 0906

PART NO. 212513-000

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COMBUSTION CHAMBER ASSEMBLY COMPONENTS

Gas Valves

Used

191956-2 Gas Valve, Natural Gas

191956-1 Gas Valve, Propane Gas

192454-3 Gas Valve, Natural Gas

192454-1 Gas Valve, Propane Gas

Gas Train

211081

211081-1

211082

Description

211082-1

INSULATION ASSEMBLY COMPONENTS

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Item Qty. Description

GB/GW

1000

GB/GW

1300

GB/GW

1500

GB/GW

1850

GB/GW

2100

GB/GW

2500

JACKET ASSEMBLY COMPONENTS:

1 ...... 1..... User Interface, Display............................... 211762.............. 211762 ............ 211762 ........... 211762 .............211762 ........... 211762

2 ...... 1..... Bracket, Control Box Support .................... 211362.............. 211362 ............ 211362 ........... 211362 .............211362 ........... 211362

3 ...... 1..... Cap, Pipe ....................................................43762-1 ............ 43762-1 ........... 43762-1 .......... 43762-2 ........... 43762-2 .......... 43762-2

4 ...... 1..... Control Box ................................................. 212458.............. 212458 ............ 212458 ........... 212458 .............212458 ........... 212458

5 ...... 2..... Gasket, Conduit.......................................... 211266.............. 211266 ............ 211266 ........... 211266 .............211266 ........... 211266

6 ...... 2..... Gasket, Main Gas Manifold ....................... 211045.............. 211045 ............ 211045 ......... 211045-1 ......... 211045-1 ........ 211045-1

7 ...... 2..... Gasket, Vent Adaptor ................................211049-1 .......... 211049-2 ......... 211049-2 ........ 211049-3 ......... 211049-3 ........ 211049-4

8 ...... 1..... Gasket, Vent Adaptor (Air Inlet) ................ 211049............ 211049-1 ......... 211049-1 ........ 211049-1 ......... 211049-2 ........ 211049-3

GB/GW

9 ..... ( ) ... Handle, Front Panel ................................. 191802(1) ......... 191802(1) ........ 191802(1) ....... 191802(2)........ 191802(2) ....... 191802(2)

10 ...... 2..... J-Box Cover .................................................. 2233 .................. 2233 ................ 2233 ............... 2233 .................2233 ............... 2233

11 ...... 2..... Junction Box ..............................................190438-4 .......... 190438-4 ......... 190438-4 ........ 190438-4 ......... 194038-4 ........ 194038-4

12 ...... 2..... Locknut, Star ................................................ 1953 .................. 1953 ................ 1953 ............... 1953 .................1953 ............... 1953

13 ...... 2..... Nipple, Chase .............................................. 41994 ................ 41994 .............. 41994 ............. 41994 ...............41994 ............. 41994

14 ..... ( ) ... Nut, Speed ................................................. 68463(4) ...........68463(4) .......... 68463(4) ......... 68463(7).......... 68463(7) ......... 68463(7)

15 ...... 1..... Panel, Display Ass’y. ............................. 212510-000 ...... 212510-000 ..... 212510-000.... 212511-001 ..... 212511-001.... 212511-001

16 ...... 1..... Panel, Front Bottom ................................... 211252............ 211252-1 ......... 211252-2 ........ 211252-3 ......... 211252-4 ........ 211252-5

17 ...... 1..... Panel, Rear Jacket ..................................... 210739............ 210739-1 ......... 210739-2 .......... 211137 ........... 211137-1 ........ 211137-2

18 ...... 1..... Panel, Right Jack. Ass’y. ........................... 211073............ 211073-1 ......... 211073-2 .......... 211282 ........... 211282-1 ........ 211282-2

19 ...... 1..... Panel, Side Access .................................... 210792.............. 210792 ............ 210792 ........... 210792 .............210792 ........... 210792

20 ...... 1..... Panel, Side Jacket ..................................... 210738.............. 210738 ............ 210738 ......... 210738-1 ......... 210738-1 ........ 210738-1

21 ...... 1..... Panel, Side Jacket ..................................... 210737.............. 210737 ............ 210737 ......... 210737-1 ......... 210737-1 ........ 210737-1

22 ...... 2..... Panel, Side Jacket Insert ........................... 211074.............. 211074 ............ 211074 ........... 211074 .............211074 ........... 211074

GB/GW

23 ...... 1..... Panel, Top Jacket ...................................... 210733............ 210733-1 ......... 210733-2 ........ 210733-3 ......... 210733-4 ........ 210733-5

24 ...... 1..... Panel, Mid-Jacket Ass'y. .............................. - - - -.................. - - - - ................ - - - - ............. 211072 .............211072 ......... 211072-1

25 ...... 1..... Plate, Conduit ............................................. 211265.............. 211265 ............ 211265 ........... 211265 .............211265 ........... 211265

26 ...... 1..... Plate, Conduit - 2 Holes ............................211265-1 .......... 211265-1 ......... 211265-1 ........ 211265-1 ......... 211265-1 ........ 211265-1

27 ...... 1..... Plate, Flue................................................... 211047............ 211047-1 ......... 211047-1 ........ 211047-2 ......... 211047-2 ........ 211047-3

28 ...... 2..... Plate, Main Gas Manifold ........................... 211046.............. 211046 ............ 211046 ......... 211046-1 ......... 211046-1 ........ 211046-1

29 ...... 1..... Plate, Top Jacket ....................................... 211142.............. 211142 ............ 211142 ........... 211142 .............211142 ........... 211142

30 ..... ( ) ... Screw, Panel.............................................. 68462(4) ...........68462(4) .......... 68462(4) ......... 68462(7).......... 68462(7) ......... 68462(7)

31 ..... ( ) ... Screw, Sheet Metal ............................... 210125-1(52) .... 210125-1(56) .. 210125-1(56) . 210125-1(56) ...210125-1(56) . 210125-1(56)

32 ...... 1..... Switch, Rocker...........................................191665-1 .......... 191665-1 ......... 191665-1 .......... 212839 .............212839 ........... 212839

33 ...... 1..... Valve, Ball 2 X 2 .........................................69022-2 ............ 69022-2 ........... 69022-2 ............. - - - - ................. - - - - ............... - - - -

34 ...... 1..... Valve, Ball 2 1/2 X 2 1/2 .............................. - - - -.................. - - - - ................ - - - - ............ 69022-3 ........... 69022-3 .......... 69022-3

35 ...... 1..... Vent Adaptor - Exhaust .............................210783-1 .......... 210783-2 ......... 210783-2 ........ 210783-3 ......... 210783-3 ........ 210783-4

36 ...... 1..... Vent Adaptor - Air Inlet .............................. 210783............ 210783-1 ......... 210783-1 ........ 210783-1 ......... 210783-2 ........ 210783-2

37 ...... 4..... Washer, Locknut ........................................ 210207.............. 210207 ............ 210207 ........... 210207 .............210207 ........... 210207

GB/GW

38 ..... ( ) ... Washer, Retaining (SPL) .......................... 68338(4) ...........68338(4) .......... 68338(4) ......... 68338(7).......... 68338(7) ......... 68338(7)

Item

Qty. Description

1000, 1300

1500

1850, 2100

2500

1000 - 1500

1850

2100, 2500

WATER HEATER CONNECTIONS:

1 ...... 1..... Flow Switch Conduit Ass'y. ............ 211156 ........ 211156 ........ 211156 ....... 211156 ......... 211156 .......... 211156 ............. 211156

2 ...... 1..... Inlet Temp Conduit Ass'y. ............ 210180-1 ..... 210180-1 ..... 210180-1 .... 210180-1 ...... 210180-1 ....... 210180-1 .......... 210180-1

3 ...... 1..... Low Water Cutoff............................ 210376 ........ 210376 ........ 210376 ....... 210376 ......... 210376 .......... 210376 ............. 210376

4 ...... 1..... Low Water Cutoff Conduit Ass'y .... 211118 ........ 211118 ........ 211118 ....... 211118 ......... 211118 .......... 211118 ............. 211118

5 ...... 1..... Outlet Conduit Ass'y..................... 210181-1 ..... 210181-1 ..... 210181-1 .... 210181-1 ...... 210181-1 ....... 210181-1 .......... 210181-1

6 ...... 1..... Pump - 1/2 HP Volute ...................... - - - - ............ - - - - ............ - - - - ........... - - - - ........... 211324 ............. - - - - ................. - - - -

7 ...... 1..... Pump - 1 HP Volute ......................... - - - - ............ - - - - ............ - - - - ........... - - - - ............. - - - - ............ 211251 ............. 211251

8 ...... 1..... Relief Valve-125 psi ......................... - - - - ............ - - - - ............ - - - - ........... - - - - .......... 98883-3 ......... 98883-3 ............ 98883-7

9 ...... 1..... Relief Valve-50 psi ....................... 210451-1 ..... 210451-2 ..... 210451-2 .... 210451-3 .......... - - - - ............... - - - - ................. - - - -

10 ...... 1..... Switch - Flow .................................. 210176 ........ 210176 ........ 210176 ....... 210176 ......... 210176 .......... 210176 ............. 210176

GB/GW

*11 ...... 1..... Tank Probe ....................................... - - - - ............ - - - - ............ - - - - ........... - - - - ......... 210211-1 ....... 210211-1 .......... 210211-1

Note: ( ) Item quantity. * Items not illustrated.

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JACKET ASSEMBLY COMPONENTS

WATER HEATER CONNECTIONS

LOW WATER CUT-OFF SWITCH

IRI MODELS - STANDARD

CSD-1 MODELS - OPTIONAL

Please update these numbers

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GB/GW

Item Qty.

Description

1000-1500

1850-2500

1000-1500 IRI

1850-2500 IRI

1 ....... 1......... Control Box Base ................................................ 212459-001.................212459-000 ................ 212459-003 .............. 212459-002

2 ....... 1 ......... Control Box Panel ............................................... 212457-001.................212457-000 ................ 212457-001 .............. 212457-000

3 ....... 1 ......... Central Control Board (CCB) ..................................211758 ....................... 211758 ....................... 211758 ...................... 211758

4 ....... ( ) ........ Flame Control Board (FCB) ..................................211759 (2) ................. 211759 (3).................. 211759 (2) ................ 211759 (3)

5 ....... ( ) ........ Relay, 120-volt .....................................................211546 (1) ................. 211546 (1).................. 211546 (2) ................ 211546 (2)

6 ....... 1 ......... Control Box Top ......................................................211109 ....................... 211109 ....................... 211109 ...................... 211109

7 ....... 1 ......... Support Bracket ......................................................212455 ....................... 212455 ....................... 212455 ...................... 212455

8 ....... 1 ......... Control Box Front Panel ..........................................212461 ....................... 212461 ....................... 212461 ...................... 212461

9 ....... 1 ......... Power Distribution Board (PDB) ......................... 211760-000.................211760-000 ................ 211760-000 .............. 211760-000

GB/GW

10 ...... 1 ......... Transformer, 150 VA .............................................. 211477 ..................... ------------...................... 211477 .................... ------------

10 ...... 1 ......... Transformer, 250 VA ............................................ ------------ ......................211673 ...................... ------------ .................... 211673

CONTROL BOX ASSEMBLY

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GB/GW

Item Qty.

Description

1000-1500

1850-2500

1 ....... 1 ......... Harness, Power Line Input .................................................................................................... 212447 ................................. 212447

2 ....... 1 ......... Harness, 120 VAC Power Distribution ............................................................................. 212410-000 ......................... 212410-001

3 ....... 1 ......... Harness, 24 VAC Power Distribution ............................................................................... 212409-000 ......................... 212409-001

4 ....... 1 ......... Harness, Transformer ....................................................................................................... 212411-000 ......................... 212411-001

5 ....... 1 ......... Harness, Relay Coil ........................................................................................................... 211949-002 ......................... 211949-002

6 ....... 1 ......... Harness, Gas Valve Relay Power (Not Shown) .............................................................. 211952-000 ......................... 211952-000

7 ....... () ........ Harness, Gas Valve Relay Power .................................................................................. 211951-001(1) ..................... 211951-001(2)

8 ....... () ........ Harness, Communication ................................................................................................ 211953-001 (1) ................... 211953-000 (2)

9 ....... 2 ......... Harness, Communication ................................................................................................... 211953-001 ......................... 211953-001

10 ...... 1 ......... Harness, Inlet Probe .......................................................................................................... 211954-000 ......................... 211954-000

11 ...... 1 ......... Harness, Outlet ECO .......................................................................................................... 211955-000 ......................... 211955-000

GB/GW

12 ...... 1 ......... Harness, External Thermostat ........................................................................................... 211956-002 ......................... 211956-002

13 ...... () ........ Harness, 120 VAC Stage Output ................................................................................... 212692-000 (1) ................... 212692-000 (2)

14 ...... 2 ......... Harness, 120 VAC Stage Output ...................................................................................... 212692-001 ......................... 212692-001

15 ...... () ........ Harness, Chasis Grounding (Not Shown) ...................................................................... 211204-407(3) ..................... 211204-407(4)

16 ...... 1 ......... Harness, Transformer Jumper (Not Shown) ...................................................................... ------------ ........................... 211204-415

17 ...... 1......... Harness, Pump Relay Contacts......................................................................................... 211963-000 ......................... 211963-000

18 ...... 3 ......... Harness, 24 VAC Output Stages ...................................................................................... 212413-000 ......................... 212413-000

19 ...... 1 ......... Harness, 24 VAC Output Stages ........................................................................................ ------------ ........................... 212413-001

20 ...... 1 ......... Harness, Tank Probe ......................................................................................................... 211989-000 ......................... 211989-000

21 ...... 1 ......... Harness, Pump .................................................................................................................. 211945-003 ......................... 211945-003

22 ...... 1......... Harness, Switch Input ....................................................................................................... 211950-003 ......................... 211950-003

23 ...... 1......... Harness, 24 VAC Output .................................................................................................. 211951-001 ......................... 211951-001

WIRE HARNESS

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Item Qty.

Description

GB 1000

GW 1000

GB 1300

GW 1300

GB 1500

GW 1500

1 ....... 1 ...... 120VAC Termination Assembly.............. 211379 ................ 211379 ................ - - - - ................ - - - - .................- - - - ................. - - - -

2 ....... 1 ...... 120VAC Termination Assembly................ - - - - .................... - - - - ................ 211378 ............ 211378 ............... - - - - ................. - - - -

3 ....... 1 ...... 120VAC Termination Assembly . ............. - - - - .................... - - - - .................. - - - - ................ - - - - ...............211376 ............. 211376

4 ....... 1 ...... 120VAC Termination Assembly................ - - - - .................... - - - - ................ 211101 ............ 211101 .............211101 ............. 211101

5 ....... 1 ...... 120VAC Termination Assembly............ 211101-1 ............ 211101-1 .............. - - - - ................ - - - - .................- - - - ................. - - - -

6 ....... 1 ...... 24VAC Termination Assembly................ 211380 ................ 211380 ................ - - - - ................ - - - - .................- - - - ................. - - - -

7 ....... 1 ...... 24VAC Termination Assembly.................. - - - - .................... - - - - ................ 211377 ............ 211377 ............... - - - - ................. - - - -

8 ....... 1 ...... 24VAC Termination Assembly . ............... - - - - .................... - - - - .................. - - - - ................ - - - - ...............211375 ............. 211375

9 ....... 1 ...... 24VAC Termination Assembly................ 211100 ................ 211100 .............. 211100 ............ 211100 .............211100 ............. 211100

10 ....... 1 ...... GW Pump Harness Assembly .................. - - - - .................. 211393 ................ - - - - ............ 211393-1 ............. - - - - ............. 211393-2

3 STAGE CONTROL SHELF WIRING HARNESSES

Item Qty. Description

GB 1850

GW 1850

GB 2100

GW 2100

GB 2500

GW 2500

1 ....... 1 ...... 120VAC Termination Assembly............ 211382 ................211382 ................. - - - - ............... - - - - .................- - - - .................. - - - -

2 ....... 1 ...... 120VAC Termination Assembly.............. - - - - .................... - - - - ................. 211385 ........... 211385 ............... - - - - .................. - - - -

3 ....... 1 ...... 120VAC Termination Assembly.............. - - - - .................... - - - - ................... - - - - ............... - - - - ...............211386 .............. 211386

4 ....... 1 ...... 120VAC Termination Assembly . ......... 211101 ................211101 ............... 211101 ........... 211101 .............211101 .............. 211101

5 ....... 1 ...... 24VAC Termination Assembly.............. 211381 ................211381 ................. - - - - ............... - - - - .................- - - - .................. - - - -

6 ....... 1 ...... 24VAC Termination Assembly . ............. - - - - .................... - - - - ................. 211387 ........... 211387 ............... - - - - .................. - - - -

7 ....... 1 ...... 24VAC Termination Assembly . ............. - - - - .................... - - - - ................... - - - - ............... - - - - ...............211388 .............. 211388

8 ....... 1 ...... 24VAC Termination Assembly.............. 211100 ................211100 ............... 211100 ........... 211100 .............211100 .............. 211100

9 ....... 1 ...... GW Pump Harness Assembly ................ - - - - ................ 211393-3 ............... - - - - ........... 211393-4 ............. - - - - .............. 211393-5

4 STAGE CONTROL SHELF WIRING HARNESSES

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IRI/CSD-1 COMPONENTS

IRI GAS TRAIN ASSEMBLY

ALARM BELL

CSD-1 MODELS - OPTIONAL

IRI MODELS - STANDARD

HIGH GAS PRESSURE SWITCH

CSD-1 AND IRI MODELS - STANDARD

COMPLETE IRI GAS TRAIN ASSEMBLIES:

• GB/GW 1000-1500 MODELS - 211502

• GB/GW 1850-2500 MODELS - 211502-1

Item Qty. Description

IRI/CSD-1 COMPONENTS:

GB/GW

1000

GB/GW

1300

GB/GW

1500

GB/GW

1850

GB/GW

2100

GB/GW

2500

1 ...... 1 ..... Alarm Bell ................................................... 211472 ............. 211472 ............. 211472.............. 211472 ............. 211472 ............ 211472

2 ...... 1 ..... Bracket....................................................... 211504 ............. 211504 ............. 211504.............. 211504 ............. 211504 ............ 211504

3 .... ( ) .... High Pressure Switch - Natural........... 192527-1(3) ..... 192527-1(3).... 192527-1(3) ..... 192527-1(4) ..... 192527-1(5) .... 192527-1(7)

...... ( ) .... High Pressure Switch - Propane .......... 192527(3) ......... 192527(3) ....... 192527(3) ........ 192527(4) ......... 192527(5) ........ 192527(7)

4 ...... 1 ..... Main Manual Shut-Off .............................. 69022-2 ............ 69022-2 ........... 69022-2 ............ 69022-3 ............ 69022-3 ...........69022-3

5 ...... 1 ..... Pilot Shut-Off Valve .................................. 200683 ............. 200683 ............. 200683.............. 200683 ............. 200683 ............ 200683

6 ...... 2 ..... Safety Shut-Off Valve.............................. 211503 ............. 211503 ............. 211503.............. 211503 ............. 211503 ............ 211503

7 ...... 1 ..... Vent, Valve .............................................. 210698-1 .......... 210698-1 ......... 210698-1 .......... 210698-2 .......... 210698-2 .......... 21698-2

Note: ( ) Item quantity. * Items not illustrated.

CSD-1 and IRI Models subsitute the following part numbers for the Gas Train Assemblies shown on pages 2-3:

•Item 11 substitute with 211082-2

•Item 13 substitute with 211081-2

•Item 12 substitute with 211082-3

•Item 14 substitute with 211081-3

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NOTES

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NOTES

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500 Tennessee Waltz Parkway, Ashland City, TN 37015

Phone: 800-433-2545 Fax: 800-433-2515

www.hotwater.com E-Mail: [email protected]

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