(212132-000) – PDF - AO Smith Water Heaters
Contents
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3. S00 GAS FIRED COMMERCIAL COPPER BOILERS FOR HYDRONIC HEATING AND HOT WATER SUPPLY APPROVED 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 Donotstore 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 Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building e Immediately call your gas supplier from neighbor s phone Follow the gas supplier s instructions e 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 A CAUTION TEXT PRINTED OR OUTLINED IN RED CONTAINS INFORMATION RELATIVE TO YOUR SAFETY PLEASE READ THOROUGHLY BEFORE INSTALLING AND USING THIS APPLIANCE USER S INFORMATION MANUAL GB GW 300 400 500 650 750 SERIES 300 301 302 303 2 STAGE UNITS WARNING Should overheating occur or the gas supply fail to shut off do not turn off or disconnect the electrical supply to the pump Instead shut off the gas supply at a location external to the appliance A WARNING Do not use this boiler if any part has been under water Immediately call a qualified service technician to inspect the boiler and to replace
4. 94 AOZ 0 Gd OG 08 0 2 02 pJ 0 duwve 1 2 Lo du voL AIUO 104 Figure 1 Drawing 211760 closed and everything else is in the proper state call for heat condition will be initiated These leads should be shorted together when a thermostat is not being used If it is desired that the thermostat control the temperature of the boiler the operating setpoint of the system should be set higher than the temperature that the thermostat is controlling to This will allow the thermostat to control the boiler When the thermostat closes a call for heat will be generated until the thermostat determines that the control temperature has been reached Air Pressure Sensors open condition indicates fault Blocked Flue CCB required Normally closed switch that opens if the flue becomes blocked during operation Powered Vent CCB optional Normally open switch that closes when the powered vent is operating properly This input is enabled disabled by a dipswitch on the CCB Blower Prover High FCB required on stages that have blowers Normally open switch that closes when the air pressures produced by the high speed blower is above the trip level Gas Pressure Sensors open condition indicates fau
5. gt IO i E CU o Drawing 211758 Figure 1A CCB L vin UB 295 eur 1 829 914 O 0914 zory 6r se NOI INIS 55 tu 22 XU Ovid 6 JEL 959 Erla oO oO pel EELA Sci 9H 000 662112 AWV14 vf cH a 80 4 Lat o a 660 90LY 90 n mon cco ceo NO yusHng Jelufl cod 9cO D s 9050 2020 8020 3080 et 208 050 508 208 D gu ln c ia ecco oO oO L1 L1 154 oO a t 050 Q 9 eo Ox emo 2020 NI SO 09 nsu Ae seo IH ug euie J T amp t ssla ogra n n HO eu Figure 1B FCB Drawing 211759 rem EN 25 000 09 2117 esa zsa B indio O 28102 74 26102
6. sequence of steps or States which are further described in the UIM Operating Procedures section 2 When power is applied to the system it enters the Initialization mode and the following automatic functions are performed Smith opening screen is displayed on the UIM e system goes through a self calibration indicated by the green running LED blinking and then staying on next the red service LED and yellow standby LEDS come on next the stage 1 service and running LEDS blink on and off followed by stage 2 stage 3 stage 4 and then back to stage 1 2 3 4 LEDS CCB FCB Dip Switches Dipswitch configurations are RED ONLY ON POWER UP These switches are only to be set at the factory or by authorized trained personnel only Once set at installation they generally remain that way for the duration of the life of the product If a switch is changed power must be cycled before the change will take effect The status of all dipswitches can be observed on the system status screen on the UIM CCB Ten Position Dipswitch Central Control Section Water Heaters Boilers Switch 1 Selection of the type of boiler application GW LW GB LB Switch 2 Trials for ignition On 1 Off 3 Switch 3 IRI Gas Valve Option On IRI Off No IRI Switch 4 Controlling Probe On Inlet Off Tank Remote Switch 5 Powered Vent On Yes Off No Switch 6 Low Water Cut Off On Yes Off No Switch 7 Low Gas On Yes Off No Swi
7. 1 Touch the MENU key 2 Scroll the gt with the down key next to USER SETTING SCREEN 3 Touch the SELECT key 4 Scroll the gt with the DOWN key until it is pointing to HIGH LIMIT DIFFERENTIAL SETPOINT Touch the SELECT key Use the UP or DOWN key to select the value you wish to enter Touch the SELECT key to accept and store the new value Operating Differential Setpoints Each of the two stages has an independent Operating Differential setpoint OPERATING DIFFERENTIAL SETPOINT ADJUSTMENT PROCEDURE oo Each of the two stages has an independent Operating Differential Setpoint The range of these setpoints is from 1 Degree F to 50 Degrees F for all models Use the following procedure to change this setpoint 2 Touch the MENU Scroll the gt with the DOWN key next to USER SETTING SCREEN Touch the SELECT key Scroll the gt with the DOWN key until it is pointing to OPERATING DIFFERENTIAL SETPOINT Touch the SELECT key Scroll the gt with the DOWN key until it is pointing to the STAGE you want Touch the SELECT KEY Use the UP and DOWN key to select the value you wish to enter Touch the SELECT key to accept and store the new value Temperature Units Temperature can be displayed in either F or C units Post Circulate Delay Time The time circulation pump will stay on after the burner is turned off The time in seconds is adjustable with the following values 45 90 180
8. and retries ignition until it completes three tries Then it will declare an error Check for Flame State The gas valve is turned on After 1 5 seconds the system checks that the gas valve relay is on If it is not the ignition trial is considered to have failed and the system advances to the Inter Purge state if any ignition trials remain otherwise an error is declared The flame sensor is checked If flame is detected the igniter is turned off and if the blower is low speed it is switched to high speed The state machine then advances to the Heating State If after 5 seconds the flame is still not sensed then the ignition trial is considered to have failed The state machine advances to Inter Purge if any ignition trials remain otherwise an error is declared Heating State The system remains in this state until the call for heat is cancelled a fault occurs The system returns to the Idle state if the call for heat is cancelled and to the appropriate fault state if a fault occur Inter Purge State The gas valve and the igniter are turned off The system goes back to the Heating Igniter State Post Purge State The gas valve and the igniter are turned off If this stage does not have a blower the system returns to the idle state Error State The gas valve and the igniter are turned off The FCB micro tells the CCB micro which error has occurred The system waits in this state until the CCB sends a command to clear the
9. any part of the control system and any gas control which has been under water INDEX PAGE LIGHTING INSTRUCTIONS esee 2 3 MAINTENANCE bbs 37 OPERATING SEQUENCE 5000 8 14 CONNECTION DIAGRAM 13 EMC5000 INSTRUCTIONS 14 18 WARRANTY testi Conn vns 19 ZA WATER PRODUCTS COMPANY ADIVISION OF A O SMITH CORPORATION www aosmithwaterheaters com PLEASE KEEP THESE INSTRUCTIONS ADJACENT TO BOILER AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE PRINTED IN U S A 0205 PART NO 212132 000 THE UNIT SHOULD NOT INSTALLED DIRECTLY ON CARPETED FLOOR A FIRE HAZARD MAY RESULT Instead the boiler must be installed on the A O Smith Combustible Floor Kit Base or concrete blocks extending beyond the full width and depth of the boiler by at least 3 76 2mm inches If the boiler is installed in a carpeted alcove the entire floor must be covered with concrete blocks or use the A O Smith Combustible Floor Kit Base FLAMMABLE ITEMS PRESSURIZED CONTAINERS OR ANY OTHER POTENTIAL FIRE HAZARDOUS ARTICLES MUST NEVER BE PLACED ON ORADJACENT TO THE BOILER OPEN CONTAINERS OF FLAMMABLE MATERIAL SHOULD NOT BE STORED OR USED IN THE SAME ROOM WITH THE BOILER Light the unit in accordance with the instructions on the lighting and operating label attached to the boiler These
10. cold purging is complete the blowers are turned off and the stage 1 blower is turned on 8 The stage 1 igniter is turned on 9 After 18 seconds the system checks that the igniter has turned on If this is ok then the system turns on the gas valve 10 After 1 5 seconds the system checks the status of the flame sensor Note If the Ignition Tries dipswitch is set for 3 tries the system will not declare an error until it tries the ignition sequence three times If it is set to 1 try then the system will declare an error anytime a fault is detected 11 The system now activates the other FCB stages depending upon a control algorithm scheme that is described below For this example it is assumed that all four stages of heat are required 12 The stage 2 blower is turned on to purge the chamber 13 After approximately 10 seconds the stage 2 igniter is turned on 14 After 18 seconds the system checks that the igniter has turned on If this is ok then the system turns on the gas valve 15 After 1 5 seconds the system checks the status of the flame sensor 16 Steps 12 through 15 are then repeated for stage 3 and 4 17 The system is now in the heating mode with all four stages on and will remain in this mode until the call for heat is satisfied or a fault occurs NOTE In standby and running modes the system constantly monitors the signals and the internal operation for faults Any detected fault will halt the heating sequence and
11. device not closing its feedback switch contacts when it should Check water line switch contacts wiring LW CO Low Gas pressure is too low Flashing HARD e Caused by the Low Gas switch being open when it should be closed Check gas line switch contacts wiring IRI Gas IRI Gas Valve did not turn on Flashing HARD e Caused by the IRI Gas Valve not closing its feedback switch contacts when it should Could also be caused problem with the relay output on the CCB Check output to IRI Gas Valve switch contacts wiring Powered Vent Power vent not running Flashing HARD e Caused by the Powered Vent device not closing its feedback switch contacts when it should Could also be caused by a problem with the relay output on the CCB Check output to powered vent switch contacts wiring High Gas Stg Gas pressure too high Flashing HARD e Caused by the High Gas switch being open when it should be closed Check gas line switch contacts wiring Inlet Probe Inlet probe shorted or open Flashing HARD e Caused when the thermistor in the probe or the wiring to the probe is shorted or disconnected Check the probe Note The thermistor and wiring can be checked by disconnecting the probe from the CCB and reading the resistance across the two active pins on the connector at the end of the probe cable The value should be approximately 10K ohms value will change slightly with changes in temperature Outlet Probe Outlet probe s
12. instructions are repeated on the following two pages Lighting Instructions for the G B W 300 through 750 models FOR YOUR SAFETY READ BEFORE OPERATING A THIS APPLIANCE DOES NOT HAVE A PILOT IT 15 EQUIPPED WITH AN IGNITION DEVICE WHICH AUTOMATICALLY LIGHTS THE BURNER DO NOT TRY TO LIGHT THE BURNER BY HAND BEFORE LIGHTING SMELL ALL AROUND THE APPLI ANCE AREA FOR GAS BE SURE TO SMELL NEXT TO THE FLOOR BECAUSE SOME GAS IS HEAVIER THAN AIR AND WILL SETTLE ON THE FLOOR WHAT TO DO IF YOU SMELL GAS DO NOT TRY TO LIGHT ANY APPLIANCE DO NOT TOUCH ANY ELECTRIC SWITCH DO NOT USE ANY PHONE IN YOUR BUILDING IMMEDIATELY CALL YOUR GAS SUPPLIER FROM NEIGHBOR S PHONE FOLLOW THE GAS SUPPLIER S INSTRUCTIONS IF YOU CANNOT REACH YOUR GAS SUPPLIER CALL THE FIRE DEPARTMENT WARNING IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE PERSONAL INJURY OR LOSS OF LIFE uy FLAMMABLE USE ONLY YOUR HAND TO PUSH IN OR TURN THE GAS CONTROL KNOB NEVER USE TOOLS IF THE KNOB WILL NOT PUSH IN OR TURN BY HAND DON T TRY TO REPAIR IT CALL A QUALIFIED SERVICE TECHNICIAN FORCE OR ATTEMPTED REPAIR MAY RESULT IN A FIRE OR EXPLOSION NOT USE THIS APPLIANCE IF ANY PART HAS BEEN UNDER WATER IMMEDIATELY CALL A QUALIFIED SERVICE TECHNICIAN TO INSPECT THE APPLIANCE AND TO REPLACE ANY PART OF THE CONTROL SYSTEM AND ANY GAS CONTROL WHICH HAS BEEN UNDER WATE
13. portion will be limited to the unexpired term of the original warranty CONDITIONS AND EXCEPTIONS This warranty shall apply only when the boiler is installed in accordance with local plumbing and building codes ordinances and regulations the printed instructions provided with it and good industry practices In addition an appropriately sized safety relief valve certified to the ASME Boiler and Pressure Vessel Code must have been installed and fresh water used for filling and makeup purposes a This warranty shall apply only when the boiler is used 1 at temperatures not exceeding the maximum setting of its operative and or high limit control 2 at water pressure not exceeding the working pressure shown on the boiler 3 when filled with boiler water free to circulate at all times and with the heat exchanger free of damaging scale deposits 4 in noncorrosive and non contaminated atmosphere 5 in the United States its territories or possessions and Canada 6 at a water velocity flow rate not exceeding or below the Boiler s designed flow rates b Any accident to the boiler any misuse abuse including freezing or alteration of it any operation of it in a modified form will void this warranty SERVICE AND REPAIR EXPENSE Under this limited warranty the warrantor will provide only a replacement part The owner is responsible for all other costs Such costs may include but are not limited to a Labor charges for service removal re
14. stage 1 to stage 2 Example 4 Boiler is initially started and the controlling temperature is at 125 see Figure 2B Stages 1 and 2 will turn on in sequence from 1 to 2 Stage 1 OFF Stage Op Setpoint Stage 1 On Stages 1 2 On Op Setpoint Control Temp Control Temp Stage 2 OFF FIGURE 2A FIGURE 2B UIM Operating Procedures EMC 5000 Energy Management Control Service Standby Running Programmable Control Monitor Diagnostic Service VS SO S Stage 1 2 3 4 Running BN SE WATER PRODLCTS COMPANY FIGURE 3 UIM The UIM receives commands from the user and displays operational information to the user via an LCD liquid crystal display up to eleven LED s and five touch switches The LCD provides information to the user by the use of 10 menu activated screens Within each of the screens helpful information can be displayed by pressing the Help button The LED s visually inform the user about the mode the system is in The touch switches allow the user to control the operation of the system folllowing status information is displayed from this screen Status Displayed ECO LW CO Blk Flue Flow Low Gas Tstat Hi Limit Pump IRI Gas Pwr IRI Gas Pwr Vent Alarm Pwr Vent Pwr True Condition Outlet temperature too high Water Level low Flue blocked Water flowing Gas pressure low Thermostat requesting heat Pump output activate
15. CONTROLLER TO DESIRED SETTING IF THE APPLIANCE WILL NOT OPERATE FOLLOW THE INSTRUCTIONS TO TURN OFF GAS TO THE APPLIANCE AND CALL YOUR SERVICE TECHNICIAN OR GAS SUPPLIER 4 REFER TO DIAGRAMS ABOVE TURN TOP KNOB OF GAS CONTROL CLOCKWISE OFF POSITION FIG 5 REPLACE CONTROL ACCESS PANEL LIGHTING INSTRUCTIONS These models have an automatic hot surface ignition system mounted on the combustion chamber panel inside the front jacket This hot surface igniter ignites the main burner gas whenever the system control calls for heat Before proceeding with operation of the unit make sure the boiler and system are filled with water and all air is expelled from the boiler radiator tank s and piping WARNING THE MAIN MANUAL GAS SHUT OFF VALVE MUST HAVE BEEN CLOSED FOR AT LEAST FIVE 5 MINUTES BEFORE LIGHTING This waiting period is an important safety step Its purpose is to permit gas that might have accumulated in the combustion chamber to clear IF YOU DETECT GAS AT THE END OF THE PERIOD DO NOT PROCEED WITH LIGHTING RECOGNIZE THAT GAS ODOR EVENIF IT SEEMS WEAK MAY INDICATE PRESENCE OF ACCUMULATED GAS SOMEPLACE IN THE AREAWITH A RISK OF FIRE OR EXPLOSION WARNING THERE IS A RISK IN USING FUEL BURNING APPLIANCES SUCH AS GAS WATER BOILERS IN ROOMS GARAGES OR OTHER AREAS WHERE GASOLINE AND OTHER FLAMMABLE LIQUIDS ARE USED OR STORED OR ENGINE DRIVEN EQUIPMENT OR VEHICLES ARE STORED OPERATED OR REPAIR
16. ED FLAMMABLE VAPORS ARE HEAVY AND TRAVEL ALONG THE FLOOR AND MAY BE IGNITED BY THE BOILER S MAIN BURNER FLAMES CAUSING FIRE OR EXPLOSION Some local codes permit operation of gas appliances if installed 18 inches or more above the floor This may reduce the risk if location in such an area cannot be avoided DANGER HOT WATER TEMPERATURES REQUIRED FOR AUTOMATIC DISHWASHER AND LAUNDRY USE CAN CAUSE SCALD BURNS RESULTING IN SERIOUS PERSONAL INJURY AND OR DEATH THE TEMPERATURE AT WHICH INJURY OCCURS VARIES WITH THE PERSON S AGE AND TIME OF EXPOSURE THE SLOWER RESPONSE TIME OF CHILDREN AGED OR DISABLED PERSONS INCREASES THE HAZARDS TO THEM NEVER ALLOW SMALL CHILDREN TO USE AHOT WATER TAP OR TO DRAW THEIR OWN BATH WATER NEVER LEAVE A CHILD OR DISABLED PERSON UNATTENDED IN A BATHTUB OR SHOWER THE WATER HEATER SHOULD BE LOCATED IN AN AREA WHERE THE GENERAL PUBLIC DOES NOT HAVE ACCESS TO SET TEMPERATURES DANGER 3 is recommended that lower water temperatures be used to avoid the risk of scalding It is further recommended in all cases that the water temperature be set for the lowest temperature which satisfies the user s hot water needs This will also provide the most energy efficient operation of the water heater and minimize scale formation SETTING THE WATER HEATER TEMPERATURE AT 120 F WILL REDUCE THE RISK OF SCALDS Some states require settings at specific lower temperatures Table 1 below shows the approximat
17. R DO NOT OPERATE APPLIANCE UNLESS UNIT IS FILLED WITH WATER AND WATER LINES ARE FULLY OPEN TOP KNOB ROBERTSHAW FIGURE A FIGURE B OFF POSITION ON POSITION _ WHITE RODGERS FIGURE A FIGURE B 2 OFF POSITION ON POSITION OPERATING INSTRUCTIONS 1 STOP READ THE SAFETY INFORMATION ABOVE ON THIS LABEL 2 SET THE SYSTEM CONTROLLER TO THE LOWEST SETTING 3 TURN OFF ALL ELECTRIC POWER TO APPLIANCE 4 THIS APPLIANCE IS EQUIPPED WITH AN IGNITION DEVICE WHICH AUTOMATICALLY LIGHTS THE BURNER DO NOT TRY TO LIGHT THE BURNER BY HAND 5 REMOVE CONTROL ACCESS PANEL 6 REFER TO DIAGRAMS ABOVE TURN TOP KNOB OF GAS CONTROL CLOCKWISE 7 TO OFF POSITION FIG A 7 WAIT FIVE 5 MINUTES TO CLEAR OUT ANY GAS THEN SMELL FOR GAS INCLUDING NEAR THE FLOOR IF YOU SMELL GAS 1 SET THE SYSTEM CONTROLLER TO THE LOWEST SETTING 2 TURN POWER SWITCH ON APPLIANCE TO OFF POSITION SWITCH LIGHT GOES OUT 3 REMOVE ACCESS PANEL TO EXPOSE GAS CONTROL TO TURN OFF GAS TO APPLIANCE STOP FOLLOW B IN THE SAFETY INFORMATION ABOVE ON THIS LABEL IF YOU DON T SMELL GAS GO TO THE NEXT STEP TURN TOP KNOB OF GAS CONTROL COUNTER CLOCKWISE TO ON POSITION FIG B REPLACE CONTROL ACCESS PANEL TURN POWER SWITCH TO ON POSITION SWITCH LIGHT COMES ON SET THE SYSTEM
18. RANTOR WITH RESPECT TO THE MERCHANTABILITY OF THE BOILER OR THE INSTALLATION OPERATION REPAIR OR REPLACEMENT OF THE BOILER THE WARRANTOR SHALL NOT BE RESPONSIBLE FOR WATER DAMAGE LOSS OF USE OF THE UNIT INCONVENIENCE LOSS OR DAMAGE TO PERSONAL PROPERTY OR OTHER CONSEQUENTIAL DAMAGE THE WARRANTOR SHALL NOT BE LIABLE BY VIRTUE OF THIS WARRANTY OR OTHERWISE FOR DAMAGE TO ANY PERSONS OR PROPERTY WHETHER DIRECT OR INDIRECT AND WHETHER ARISING IN CONTRACT OR TORT a Some states or provinces do not allow the exclusion or limitation of the incidental or consequential damage so the above limitations or exclusions may not apply to you b This warranty gives you specific legal rights and you may also have other rights which vary from state to state or province to province Fill in the following for your own reference Keep it Registration is not a condition of warranty The model and serial number are found on the boiler s rating plate Owner Installation Address City and State or Province Postal Zip Code Date Installed Model No Serial No Dealer s Name Dealer s Address PhoneNo FILLIN WARRANTY AND KEEP FOR FUTURE REFERENCE 19 WATER PRODUCTS COMPANY 5621 W 115TH STREET ALSIP IL 60803 Phone 800 433 2545 Fax 800 433 2515 www aosmithwaterheaters com 20
19. S O93 WONYA EMO HIMO Y AS LONI ar 2 3808d 3einIveradiNaL LIINI MaMod38odd LIINI vin MOTBBIINSI RE MB Svo tal A NEALSY HOLIMS MOH HOLIME MOH Agam AAA SVO SATWA Svo eir 5 REPIT OUR aoe TOU SVS goo auvog eee DYNOLdO v Civ NOILdO Nain138 Svo MOT OA SVE HOM NEALSY HOLIMS SVO HOIH JOSINOO TVHIN3O E ACH CREE 1 HOLIMS Svo HOIH HOLMS 599 alvi aaADad aaWDn8 B REMO SE fol S A wodaaAoad HIMOA 2 WET fair auvoa COwNDudo See izro ozr 6 ana J wry GYNOWO Nain 138 HOLIMS 3301 HSLVAN MOT 330110 MOT divo 2 CivNOILdO ONS 1N3 d CivNOLLdO NEALSY HOLMS HIMO d INJA CWNOWdO LN3A z SNOLLWOINNWWOS TYNAL J ur NelnL38 WWLSOWSSHL WNL XS 1 p IVISOWHSSHL WNAI NENLSY 3enivea dia Figure 4 DIAGRAM Drawing 211769 13 cold purge time The FCB will go into fault mode if the blow
20. The Boiler is equipped with a blocked vent shut off system which will close the gas valve and shut off the main burner gas when there is excessive pressure in the vent system due to a partially or completely blocked vent system DO NOT ATTEMPT TO OPERATE THE BOILER if this situation occurs Shut the boiler off before performing all the steps shown TO TURN OFF GAS TO APPLIANCE section of the Lighting and Operating Instructions Contact a qualified service agent to inspect the unit and vent system and correct the problem VENT SYSTEM The flue products are corrosive in nature and if the boiler is vented horizontally the flue gases are at a higher pressure than the surrounding air pressure Inspection of the boiler and vent system is necessary to insure that flue gas leakage to the surrounding area does not occur Inspect the external surfaces of the vent system every 3 months for corrosion and leakage Inspect the vent terminations for corrosion and foreign matter which may be blocking the exhausting flue products Call a qualified service agent to replace or repair any corroded or leaking parts A qualified service agent must inspect the internal surfaces of the vent system and the boiler at least once a year BURNER SYSTEM To maintain safe operation and the greatest efficiency for the boiler observe the burner flame through the observation port on the jacket panel once a month for proper flame characteristics The burne
21. There are approximately 80 different faults that can be detected Some of the faults are caused by internal problems and some by external causes The faults create different types of system lockouts shut down Hard lockouts are serious problems that require the user to manually restart system Soft lockouts can be reset by the user or after 60 minutes the system will automatically clear the error and restart Auto Reset lockouts will monitor the cause of the fault and if the fault clears itself the system reset itself Faults with Immediate Reset lockouts are caused by faults that are momentary in nature The fault is recorded and the system immediately resets itself The following table shows the fault messages and some possible troubleshooting hints TROUBLESHOOTING IGNITION SYSTEM Fault Messages and Lockout Status stage number 1 or 2 Fault Displayed Description Red LED Lockout Display Fail Communications with UIM interrupted Continuous Auto Reset e Check communication cable to Try moving to other Internal Communications connector CCB Also check the connectors where the cable is plugged in for best connecting wires Comm Fail Stg Communications with FCB interrupted Continuous Auto Reset e Same as above Also try swapping FCB and communications cables Low AC Voltage Line voltage less than 90 vac Continuous Auto Reset e Check incoming power line for loss of voltage May also be caused by a power l
22. alid When cleared it is moved to the Error History Screen The system will automatically jump to this screen when an error is detected It will also go to this screen upon power up if an error was still valid when power was turned off NOTE Errors are cleared from this screen by pressing the select key Error History Screen This screen displays a list of the last 9 errors with timestamps that have occurred The last error to occur is displayed first If a new error occurs this screen is presented to display the error Reload Defaults Screen From this screen the user can restore the factory default values for screen adjustable configurations by pressing the Select key The values restored are as follows GW Models Oper Setpnt Operating Setpoint 145 F 63 C Stage1 Diff Operating Setpoint Differential 3 F 2 C Stage2 Diff Operating Setpoint Differential 6 F 3 C Hi LImit High LImit Setpoint 210 F 99 C Hi Limit Dif High Limit Differential 20 F 11 C GB Models Oper Setpnt Operating Setpoint 190 F 88 C Stage1 Diff Operating Setpoint Differential 3 F 2 C Stage2 Diff Operating Setpoint Differential 6 F 3 C Hi Llmit High Llmit Setpoint 230 F 110 C Hi Limit Dif High Limit Differential 20 F 11 C Both Models Tempert Units Temperature Units F Post Cir Secs Post Circulation pump delay 45 seconds Network Address Network Address non val
23. bled the powered vent and the IRI gas valve are turned on Acommand is sent to all active stages to cold purge the system Cold purging clears out any combustion gas that may be in the combustion chamber When purging is complete the system moves to the Heat State Heat Stages 1 4 The system will command the FCB micros to start their heat sequence starting with stage 1 Stages 2 through 4 will be activated in order based on an algorithm that determines how much heat is needed The system will remain in this state until the heat request is satisfied the Tstat is opened or a fault occurs Soft Fault State See Fault Description section for list of soft and Auto Reset faults The CCB turns off the Powered Vent and the IRI Gas The pump remains on for the selected post circulate time to cycle the hot water out of the boiler The FCB s are commanded to shut down and the Alarm output is turned on The green LED turns off and the red Service turns on The CCB remains in this state until one of the following occurs One hour passes Soft fault automatic restart after one hour If Communications error system will automatically restart when communications are reestablished If user presses Select key while current error screen is displayed Hard reset If high limit error the outlet temperature drops below the high limit trip point minus the high limit differential outlet water temperature drops to safe level The fault is l
24. ctory EEProm Error Not implemented ROM Failure Stg ROM contents incorrect Flashing HARD e Caused when the Read Only Memory on one of the FCB micros operates improperly Contact factory ROM Failure CCB ROM contents incorrect Flashing HARD e Caused when the Read Only Memory on the CCB micro operates improperly Contact factory Hdwr Short Stg FCB output pin shorted Flashing HARD e Caused when pin on one of the FCB micros is not in the output state it should be in Contact factory Hdwr Short CCB CCB output pin shorted Flashing HARD e Caused when pin on the CCB micro is not in the output state it should be Contact factory CPU Fail Stg FCB processor failed internal check Flashing HARD e Caused when one of the FCB micros does not pass its internal checks Contact factory CPU Fail CCB CCB processor failed internal check Flashing HARD e Caused when the CCB micro does not pass its internal checks Contact factory RAM Failure CCB CCB Ram check failed Flashing HARD e Caused when the CCB micros Random Access Memory operates incorrectly Contact factory FCB Comm Timeout FCB did not receive command from CCB Continuous SOFT e Caused when communications between the CCB and the FCB are interrupted May occur when a surge of power on a nearby device i e arc welder creates an EMI burst Not a serious problem if it occurs rarely No Flow Water is not flowing Continuous SOFT e Caused by the flow switch being
25. d IRI output relay activated IRI Gas Valve on Power Vent running Alarm output activated STAGES 1 to 4 Blower pressure sufficient Blower High output activated Blower pressure sufficient Blower low output activated BlwHi Prv Blw Hi BlwLo Prv Blw Lo Ignt Cur Ignit Gas Relay Hi Gas Flame Igniter output is activated Gas output relay activated Gas pressure too high Flame detected The operation of these parts is described below UIM Screens On all screens a double vertical bar appears on the right side of the display each time a key is touched to indicate that a key has been activated On several screens an indicator gt appears on the left side of the display to indicate the active line The Up Down keys are used to move the indicator to the desired line and the Select key is pressed to select the line Also on most of the screens up down arrows appear on the right side of the screen to indicate that there are additional lines either above or below the displayed four lines Menu Screen Displayed when the user presses the Menu key This screen is the selection point for the other 9 screens Temperature Screen Displays the sensed temperatures of the Outlet Inlet and Tank probes Also displayed is the calculated Delta T Outlet minus Inlet for the system Shorted Short and disconnected probes are also displayed System Status Screen This screen is used to view the status of
26. distributes power to the system and contains the system fuses Dual stage control is accomplished by means of an internal communication network and the FCB s One FCB is required for each stage beyond initial first stage The CCB also contains an external communications system to allow for connection to a PC a modem or an EMS system Through this connection multiple boilers can also be linked together caution The internal communications cables should never be connected to the external communications connectors and vice versa There are several microcontrollers used on the board Three on the CCB two on the FCB and one on the UIB These micros control the temperature and ignition control functions for the boiler Inherent in the design are the normal operating sequences and safety features associated with a gas ignition control system The system continuously performs various diagnostic tests to verify proper appliance and control operation Should an unsafe condition occur the control will shut down the burner and display a red fault light as well as indicate the cause of the fault on the display The operating programs for the system are stored in permanent memory inside the micros User selectable operating parameters and a history of detected faults are stored in re writable memory in the micros A loss of power does not affect either of the memories Inputs To CCB and FCB Temperature Sensors Temperature probes CCB ou
27. dle State If a Silicon Nitrite igniter is being used then its condition is determined and any error is declared The system will remain in this state until the CCB requests a heating cycle or a cold purge The blowers igniter and gas relay are turned off Pre Purge State If the stage does not have a blower this state is skipped and the system advances to the Heat Igniter State Otherwise the Hi Speed Blower is turned on After 10 to 34 seconds 34 12 seconds for cold purging the system switches to the Heat Igniter State If the blower on this stage is a 2 speed then the Hi Speed is turned off and the Low Speed is turned on before Switching states Heat Igniter State The igniter relay is turned on and a go command is sent to the Silicon Nitrite micro Responses returned from the current feedback sensor and the Silicon Nitrite micro are checked to determine which type of igniter is being used Note This is only done the first time the igniters are fired after power is applied This allows the user to change igniter types after shutting off power If the current feedback sensor is still active after approximately 18 seconds have passed or the Silicon Nitrite micro has returned a signal indicating that the igniter has fired properly then the system advances to the Check for Flame state If the signals do not occur then an error is declared unless the Ignition Tries dipswitch is set to three Then the system advances to Inter Purge state
28. e time to burn relationship for normal adult skin Table 1 Risk of Scalds Temperature Time to Produce 2nd amp 3rd Setting Degree Burns on Adult Skin Over 170 Nearly instantaneous 160 About 1 2 150 About 1 1 2 140 Less than 5 seconds 130 About 30 120 or less More than 5 minutes Water heater life depends upon water quality water pressure and the environment in which the water heater is installed Water heaters are sometimes installed in locations where leakage may result in property damage even with the use of a drain pan piped to adrain However unanticipated damage can be reduced or prevented by a leak detector or water shutoff device used in conjunction with a piped drain pan These devices are available from some plumbing supply wholesalers and retailers and detect and react to leakage in various ways Sensors mounted in the drain pan that trigger an alarm or turn off the incoming water to the water heater when leakage is detected Sensors mounted in the drain pan that turn off the water supply to the entire home when water is detected in the drain pan Water supply shutoff devices that activate based on the water pressure differential between the cold water and hot water pipes connected to the water heater Devices that will turn off the gas supply to a gas water heater while at the same time shutting off its water supply BLOCKED VENT SHUT OFF SYSTEM
29. earth ground connection Also check that line voltage does not exceed 132 vac rms Igniter Hdwr Stg Hardware problems with Si3NA circuit Flashing HARD Gas Relay Stg Gas Valve Relays did not turn on Flashing HARD Flame Stg Flame not detected Flashing HARD Blwr Low Stg Low speed blower relay did not turn on Flashing HARD e Caused by a failure of a relay on the FCB Contact factory Blwr Hi Stg High speed blower relay did not turn on Flashing HARD e Caused bya failure of a relay on the FCB Contact factory Short Cycle Cond Burner cycle rate above 30 per hour SEE BELOW e Caused when a stage performs more than 30 heat cycles one hour When this fault is detected the system continues to operate but the calls for heat are forced to occur no faster than every 180 seconds While this system is in this short cycle operating mode the yellow Standy LED flashes Check system setup and operation 17 Other troubleshooting hints Input switches can be easily checked by observing their activation on the UIM System Status screen Force the boiler to remain in the Standby mode by opening the Thermostat input or by setting the operating setpoint to the minimum so that the system does not request heat Then short out the contacts on the switch and verify that an asterisk appears next to the appropriate input on the screen If it does not then look for the problem to be in the wiring or connectors between the flow switch a
30. eed no igniter no blower 17234567 8 flame not checked No High Gas Stored values are recalled from memory e Configuration dipswitches are read e Pending faults are recalled Micros on all boards start running indicated by a flashing Yellow LED near each micro e Input sensors are read Communications between micros and boards is established FCP s configurated with the number of ignition trials to run 3 After initialization is complete approximately 10 seconds the system turns the green LED off and goes to the standby mode yellow Standby LED on unless a previously stored fault has been recalled which will send the system into the service model red Service LED on In standby mode the display shows the temperature screen and in fault mode the current error screen is displayed 4 The system then compares the temperature read from the controlling probe inlet or tank to the setpoint temperature If the temperature is less than the operating setpoint minus the differential temperature and the thermostat input is closed then a call for heat is established and the system shifts to the run mode green Running LED turns on 5 The heating sequence begins by applying power to the pump and if selected the powered vent and the IRI gas valve 6 After a few seconds the High Speed Blower on all stages with the blower dipswitch turned on are turned on to perform a cold purge of the chamber 7 After
31. er prover does not activate after 15 seconds This time allows the blower relay to activate the blower to come up to speed and the response from the blower prover to be filtered User Settings Screen Each setpoint or user setting has either a limited selection of values or a limited range of values The Up Down keys are used to change values After changing an item the Select key is pressed to accept the change or the Menu key is pressed to reject the change and restore the item to its original value The following setpoints can be changed Operating Setpoint This setpoint sets the base temperature for the control algorithm OPERATING SETPOINT ADJUSTMENT PROCEDURE The system has a standard programmable Operating Setpoint range of 70 Degrees F to 190 Degrees F for a GW and of 70 Degrees F to 220 Degrees F for a GB The user can easily change the Operating Setpoint at any time by using the following procedure When any configuration or setpoint is changed and the Select key touched the new value is IMMEDIATELY saved to non volatile memory 1 2 Touch the MENU key Scrollthe gt with the DOWN nextto the USER SETTING SCREEN Touch the SELECT key Scroll the gt with the DOWN key until it is pointing to OPERATING SETPOINT Touch the SELECT key Use the UP or DOWN key to select the value you wish to enter Touch the SELECT key to accept and store the new value High Limit The outlet temperature probe co
32. error Then the Silicon Nitrite micro is reset and the system returns to the idle state Cold Purge State Cold purge occurs when the CCB micro commands all blowers to go on before lighting the first stage to clean the unit of gases This state normally lasts approximately 32 seconds but on a special situation can last up to 5 minutes If on the first call for heat after power up any blower prover switch is open this state will take up to 5 minutes before declaring an error This special mode is used by service technicians to adjust the blower shutters The CCB will wait the normal cold purge time normally 32 seconds before checking for activation of all active blower provers If all are active at this time the CCB cancels the cold purge request After the first cold purge has been done a flag is set to prevent further activation of the shutter adjust 5 min delay Any further requests for cold purge will last the normal 00972 O30 901 3dAL NOLLWINSNI TAHMA
33. horted or open Flashing HARD e Caused when the thermistor in the probe or the wiring is shorted or disconnected Check the probe Note the thermistor and wiring can be checked by disconnecting the probe from the CCB and reading the resistance across the two active pins on the connector at the end of the probe cable The value should be approximately 10K ohms value will change slightly with changes in temperature Tank Probe Tank Remote probe shorted or open Flashing HARD e Caused when the thermistor in the probe or the wiring is shorted or disconnected Check the probe Note the thermistor and wiring can be checked by disconnecting the probe from the CCB and reading the resistance across the two active pins on the connector at the end of the probe cable The value should be approximately 10K ohms value will change slightly with changes in temperature Igniter Stg Igniter current is too low Flashing HARD e Caused by a low current draw problem with the Silicon Nitride igniter This may occur if the igniter is old damaged or disconnected and no longer draws the proper level of current This condition will affect the ability of the igniter to get hot enough to fire the gas properly Check the igniter and its associated wiring Igniter Pwr Stg Improper power applied to Si3N4 circuit Flashing HARD Caused by improper line power being applied to the Silicon Nitride circuitry Check line connections Paying particular attention to the
34. id address UIM Touch Switches Below the LCD display are five touch switches or keys that the operator uses to operate the system Menu Key Pressing this key activates the menu screen where the other screens can be accessed Select Key This key performs several functions Screens can be selected from the menu screen by pressing this key when the gt appears next to the screen desired 15 On the User Settings screen items that appear next to a gt symbol can be selected with this key If a setpoint item is selected the gt will then flash slowly to indicate that the item has been Down keys then used to change its value From the Current Error Screen this key is used to reset the system from an error Up and Down Keys These keys are used to move upwards and downwards in screens to reach a desired item and to change setpoints and user settings They have an auto increment decrement feature for some of the configurations and values When you first press one of the keys and value changes by 1 count then wait 1 2 second and changes slowly until the key is released or if held for 3 or more seconds it will change the value quickly Help Key Pressing the Help key from any screen displays helpful information about that screen From the menu screen general help information is displayed as to how to use the user interface To return to the previous screen press the Help or Select keys
35. ine brown out momentary loss of voltage Low 24VAC Voltage from transformer less than 18 vac Continuous Auto Reset e Check transformer output Should be over 24vac May be caused by excessive current drain or a faulty transformer Brown Out Reset Indicates a brown out reset occurred e Caused by a momentary dip in voltage on the CCB 5vdc power bus Contact factory Not considered a serious problem if it only occurs on very rare occasions Timeout Reset Indicates a watchdog reset occurred e Caused when the micro executes the software in an improper way Contact factory Not considered a serious problem if it only occurs on very rare occasions CCB Overflow Stack overflow recorded in history only Immediate Reset e Caused when the micro overfills its memory stack Contact factory Not considered a serious problem if it only occurs on very rare occasions CCB Underflow Stack underflow recorded its history only Immediate Reset e Caused when the micro underfills its memory stack Contact factory Not considered a serious problem if it only occurs on very rare occasions Sequence Err Incorrect flow of critical code Flashing HARD e Caused when the micro executes software code in an incorrect manner Contact factory A D Fail CCB Error in analog input reading Flashing HARD e Caused when the Analog to Digital converter section of the micro operates improperly Contact fa
36. ith the voltage and current level provided Pump CCB 120vac required on systems that do not have an external pump Provides electrical power to directly operate a pump or the coil of an externally connected contactor Powered Vent CCB 24vac optional Provides electrical power to operate a powered vent Low and High Speed Blowers FCB 120vac required on stage 1 and on stage 2 of a 4 stage system and optional on others Independent outputs that provide power to operate low and high speed blower output Dip switches on the FCB s enable disable the use of blowers on stages 2 3 and 4 gniter FCB 120vac required on stage 1 and on stage 2 of a 4 stage system and optional on others Provides power to operate the NSI igniters Dip switches on the FCB s enables disables the use of an igniter on stages 2 3 and 4 Gas Valve FCB 24vac required Provides power to activate the gas valve The gas valve cannot be activated when the ECO contacts are open Direct Connection Output Low Water Cut Off CCB 24vac optional Directly connected to the 24 vac line to provide power to operate an external LWCO device Line Polarity Indicator amp Fuse Protection CCB FCB Indicator Lamps amp Fuses A green LED is mounted on the PDB to indicate when line voltage is applied The PDB also contains a yellow LED a red LED and a test run jumper that are used during installation to verify proper power connecti
37. ls The boiler should be provided with air from outdoors when installed in environments having corrosive atmospheres CIRCULATION PUMP Refer to the pump manufacturer s schedule of maintenance for frequency and method of lubricating the pump and motor Inspect the pump once a month for leaky mechanical seals and or O rings and loose or damaged components Contact a qualified Service agent to replace or repair parts as required ELECTRONIC HOT SURFACE IGNITION CONTROL BOARD The EMC5000 control system is a fully integrated state of the art electronic control system It consists of sensors output devices a power switch a 24vac transformer wiring and the following printed circuit boards Central Control Board CCB Flame Control Board FCB User Interface Board UIB See Figure 1A See Figure 1B This part of the User Interface Module UIM See Figure 3 Power Distribution Board PDB See Figure 1C Touch Sensor Board TSB This is part of the User Interface Module UIM See Figure 3 The CCB contains circuitry for both master control and flame control for the first stage The FCB contains circuitry for flame control on up to one additional stage Dip switches on the CCB and FCB are used to configure the system The UIB and TSB are included in the User Interface Module UIM along with a 4 line by 20 character LCD display The PDB provides connection points for input power the water pump and the transformer It also
38. lt Low Gas CCB optional Normally open switch that closes when the gas pressure rises above the trip level This input is enabled disabled by a dipswitch on the CCB Hi Gas FCB optional Normally closed switch that opens in the gas pressure exceeds a set value This input is enabled disabled by a dipswitch on the CCB and FCB s Water Level Sensor open conditions indicates fault Low Water Cut Off CCB optional Normally closed switch opens if a low water condition occurs This input is enabled disabled by a dipswitch on the CCB Water Flow Sensor Flow CCB required Normally open switch that closes when flow exceeds a set value IRI Gas Valve Sensor RI Gas Valve CCB optional Normally open switch that closes when the IRI Gas Valve is operating correctly This input is enabled disabled by a dipswitch on the CCB Flame Sensor Flame FCB required on stage 1 and on stage 2 of a 4 stage System optional on others Returns a signal to the microprocessor if flame is detected in the burner This input is enabled disabled by a dipswitch on the FCB Outputs from CCB and FCB s Relay Contact Outputs IRI Gas Valve CCB 120vac optional Provides electrical power to operate an IRI Gas Valve device Alarm CCB 24vac optional Provides electrical power to operate on external alarm This can be an audio device i e Sonalert a visual device lamp or any other device that will operate w
39. nd the CCB When troubleshooting a particular problem the heating sequence time can be shortened by turning off the dipswitches for operation devices that are not needed during troubleshooting The pump can be activated during the Standby mode by changing the post circulate time to continuous All Hi Speed blowers can be activated for 5 minutes by opening any Hi Speed blower prover switch prior to turning on the power This activates the shutter adjust mode During this time activation of all of the blower prover switches can be checked on the system status screen Opening the Thermostat input leads will force the system to remain in the standby mode 18 10 Running the system with the gas turned off will allow the system to run through all operating steps up to flame sensing Proper operation of the flame sensing circuit can be almost completely verified through the use of a 14007 diode The anode end of the diode should be connected to the appropriate flame sense lead and the cathode end bar of the diode should be connected to the case of the boiler earth ground connection Gas is not needed for this procedure and therefore should be off It is also desirable to disable the command for heat by opening the thermostat leads After apply power the system should declare an error because flame is being sensed at the wrong time Shift to the System Status screen and scroll down to the appropriate Flame input The asteri
40. ntains both an ECO switch and a thermistor for temperature measurement The sensed outlet temperature is used for the automatically resettable High Limit setpoint If the sensed outlet temperature exceeds the High Limit setpoint a soft lockout condition will occur and the burner will be shut off This fault condition is automatically cleared when the temperature drops below the high limit setpoint minus the high limit differential HIGH LIMIT SETPOINT ADJUSTMENT PROCEDURE The High Limit setpoint has a range of 90 Degrees F to 210 Degrees F for a GW and a range of 90 Degrees to 235 Degrees F for a GB Use the following procedure to change the automatically resettable High Limit Setpoint 1 2 Touch the MENU key Scroll the gt with the DOWN key next to USER SETTING SCREEN Touch the SELECT key Scroll the gt with the DOWN key until it is pointing to HIGH LIMIT SETPOINT Touch the SELECT KEY Use the UP and DOWN key to select the value you wish to enter Touch the SELECT key to accept and store the new value High Limit Differential The outlet temperature must be below the automatic High Limit setpoint minus the High LImit Differential setpoint before a call for heat can be generated 14 HIGH LIMIT DIFFERENTIAL SETPOINT ADJUSTMENT PROCEDURE The High LImit Differential Setpoint has a range of 1 Degree to 50 Degrees F for all models Use the following procedure to change the High Limit Differential Setpoint
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42. ogged in the error history when the fault state is exited Hard Fault State See Fault Description section for list of soft and Auto Reset faults The CCB turns off the Powered Vent and the IRI Gas The pump remains on for the selected post circulate time to cycle the hot water out of the boiler The FCB s are commanded to shut down and the Alarm output is turned on The green LED turns off and the red Service turns on and off flashes The only way to exit this state is for the user to press the Select key while the current error screen is displayed The fault is logged in the error history when the fault state is exited While the CCB is in the Heating mode the activated FCB stage moves from Idle to Pre Purge to Heat Igniter to Check for Flame and then to Heating The process waits in this state until the call for heat is satisfied the thermostat input is opened or a fault occurs When heat is satisfied the sequence continues to Post Purge and then back to ldle If three tries for ignition has been selected on the CCB dipswitch and flame is not detected at the appropriate time then the sequence moves to the Inter Purge state for 15 seconds and the FCB heat sequence is repeated If flame is still not detected after the third try the process declares a fault jumps out of sequence and goes to the error state Other types of faults detected at any time will also cause a jump to the error state Description of FCB control states I
43. ons A red LED on the CCB is used to indicate when the 24 vac input fuse has blown The FCB s also have fuses on their 24vac power line Recommended replacement fuses are Littlefuse p n 29707 5 for the 7 5 amp CCB fuse and Littlefuse p n 297003 for the 3 amp FCB fuses Repeated failure of fuse is an indication of failure to some part of the system Yellow LED s are located near the micros on the CCB and FCB s These LED s are heartbeat indicators and blink approximately twice per second to indicate that the micros are running The blink rate of the LED next to the micro that controls the silicon nitrite igniter will change when the igniter is being powered and when a fault is detected with the operation of that igniter Igniters The Silicon Nitride igniters are activated from a triac on the board that is controlled by a dedicated microcontroller and associated circuitry This circuit monitors the igniter operation closely and informs the CCB and FCB micros when faults are detected A yellow heartbeat LED located next to the dedicated micro flashes a two digit code when faults are detected Appliance Operating Sequence NOTE The following sequence is based on a four stage system with all options and two speed blowers It is characteristic of most system configurations 1 The EMC5000 controller has four modes of operation Initialization Standby Running and Service The internal CCB and FCB micros control these modes through a
44. open when it should be closed Check water lines pump flow switch contacts wiring Blower Prov Stg blower pressure is too low Continuous SOFT e Caused by either the High Speed or Low Speed blower prover switches being open when they should have been closed Check blowers switch contacts wiring and for air leaks 16 Blocked Flue Flue is Blocked Continuous SOFT e Caused by the blocked flue switch contacts being open when they should have been closed Check for flue blockage Switch contacts wiring High Limit Outlet temp exceeded high limit setpoint Continuous Auto Reset e Caused when the temperature of the outlet probe exceeds the high limit setpoint This is an internal software limit switch and not an actual device Check that the over temperature is not being caused by improper setup or operation of the boiler ECO fault Outlet temp is too high Flashing HARD Caused when the ECO a thermostat contacts in the Outlet probe are open when they should be closed Fault may be due to high outlet temperature bad switch contacts in the ECO or disconnected wiring Note The ECO can be checked by disconnecting the outlet probe from the CCB and reading the resistance across the two active pins on the connector at the end of the probe cable The value should be approximately 0 ohms when the temperature of the probe is less than 220 F Low Water Water level is too low Flashing HARD e Caused by the Low Water Cut Out
45. or continuous If the continuous value is selected the pump will remain on at all times and the post circulate state time will be set at 45 seconds Network Address This is a unique number assigned to this boiler to differentiate it from other boilers or water heater on the same A O Smith proprietary network A valid Network Address can be any number from 1 to 31 It is set by default to zero which is an invalid address The boiler will not communicate until it is changed to a valid and unique number This prevents two units from trying to respond to the same request from the PC or supervisory network device Configuration Settings Screen Displays the status of the dipswitches installed on all boards as described on page 9 Log amp System Info Screen Displays the following information Elapsed hours of operation Total time system has been powered up Number of running minutes Number of minutes system has been in the run mode Number of cycles for each stage Number of times stage has been in heat mode Kbtu rating of the boiler 0 to 5750Kbtu in 10Kbtu increments The software revision level of the CCB and FCB micro controllers Current Error Screen Displays the last error that the system has detected plus a timestamp of when the error occurred The timestamp is based on the elapsed hours value at the time the error occurred It is displayed in hours and minutes This error remain displayed as long as it is still v
46. or press Menu key to go to the menu screen If a small down arrow appears in the lower right hand corner then there is off screen content below what is displayed Press the down arrow to scroll down to this information After scrolling down an up arrow will appear in the upper right hand corner to indicate off screen content above what is displayed UIM LED s The three LED s to the right of the LCD indicate the status of the overall system The red LED indicates that a fault has been detected and the system has stopped running It is on continuously for soft faults and flashes for hard faults The Yellow LED indicates that the boiler is in a ready mode waiting for a call for heat command When on continuously the Green LED indicates that the system is in the heating mode If it is flashing it indicates that the UIB is in the initialization mode when the touch switches are being calibrated On multiple stage boilers there are also eight LED s on the lower right that indicate the state of the individual FCB s The red LED s are only on when the main red LED is on and indicate which FCB has the error The green LED indicates when flame is proved on that particular stage unless the dipswitch for sensing flame is turned off Then the LED indicates that the gas valve has turned on Fault Messages and Troubleshooting Guide The EMC5000 system does excessive self diagnostics and displays detected faults on the UIM display in an easy to read manner
47. ow Speed Blower Prover when either the High or Low Speed Blowers are on Igniter Current for an on condition approximately 18 seconds after the Igniter is turned on until the igniter is turned off and an off condition at all other times Flame for an on condition approximately 5 seconds after the gas valve is turned on until the valve is turned off and at all other times for an off condition Control Status Screen Displays the software that the CCB and FCB micros are in The CCB has 8 possible states and the FCB s have 9 The normal CCB states sequence is to move from Idle to Pre Circulate then to Heating Stage 1 4 when a call for heat is initiated Once heat has been satisfied or the Total is opened the sequence moves to Post Circulate and then back to Idle If a fault occurs at any time the process jumps out of sequence and goes directly to the appropriate Hard or Soft Fault state Description of CCB control states Idle The yellow Standby LED is turned on and the system waits for a heat request determined by the Thermostat and controlling probe inputs All outputs are off in this state except that if the Post Circulate time is set to continuous the pump will be on When the heat request is received the system moves to the Pre Circulate state e Pre Circulate The yellow LED is turned off and the green Running LED is turned on The green LED will remain on for all other states except the fault states If ena
48. pair or reinstallation of the component part b Shipping delivery handling and administrative charges for forwarding the replacement part from the nearest distributor and returning the claimed defective part to such distributor C All cost necessary or incidental for any material and or permits required for installation of the replacement LIMITATIONS ON IMPLIED WARRANTIES Implied warranties 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 allow limitations on how long an implied warranty lasts so the above limitation may not apply to you CLAIM PROCEDURE Any claim under the warranty should be initiated with the dealer who sold the boiler or with any other dealer handling the warrantor s products If this is not practical the owner should contact U S Customers Canadian Customers A O Smith Water Products Company A O Smith Enterprises Ltd 5621 West 115th Street P O Box 310 768 Erie Street Alsip IL 60803 Stratford Ontario N5A 6T3 Telephone 800 323 2636 Telephone 800 265 8520 a The warrantor will only honor replacement with identical or similar parts thereof which are manufactured or distributed by the warrantor b Dealer replacements are made subject to in warranty validation by warrantor DISCLAIMERS NO OTHER EXPRESS WARRANTY HAS BEEN OR WILL BE MADE ON BEHALF OF THE WAR
49. rs should display the following characteristics Provide complete combustion of gas Cause rapid ignition and carry over across all burners and across the entire burner Give quiet operation during ignition burning and extinction Cause no excessive lifting of flames from the burner ports If the preceding characteristics are not evident check for accumulation of lint or other foreign material that restricts the inlet air or burner ports Ensure there is the proper amount of air to the burner Flame lifting from the burner is caused by too much air to the burner The burners must be inspected by a qualified service technician at least once a year DO NOT STORE COMBUSTIBLE MATERIALS GASOLINE OR OTHER FLAMMABLE VAPORS LIQUIDS IN THE AREAOF THE APPLIANCE NONCOMPLIANCE MAY RESULT IN FIRE OR EXPLOSION DO NOT OBSTRUCT THE FLOW OF COMBUSTION OR VENTILATION AIR TO THE APPLIANCE CHEMICAL VAPOR CORROSION Boiler corrosion and component failure can be caused by airborne chemical vapors Spray can propellants cleaning Solvents refrigerants calcium or sodium chloride water softener salts waxes and process chemicals are typical compounds that are potentially corrosive These materials are corrosive at very low concentration levels with little or no odor to reveal their presence Products of this sort should not be stored near the boiler Air which is brought in contact with the boiler should not contain any of these chemica
50. shift the system to the service mode where the detected fault will be displayed Temperature Setpoints System Control Algorithm The boiler has a hysteresis type control which means that it will begin heating the water when the temperature sensed by the control probe inlet or tank falls below the operating setpoint minus the differential setpoint for stage 1 It will stop heating the water when the temperature rises to the operating setpoint If the system has multiple stages then the differential setpoint for each stage is also subtracted from the operating setpoint The following examples will further explain this operation Setup 2 stage system operating setpoint 140 stage 1 to 2 differential setpoints 10 Example 1 Temperature begins at 150 and drops to 90 see Figure 2A At 140 the system remains in idle mode As the temperature drops to 130 140 10 stage 1 turns on and stage 2 remains off At 120 stage 2 also turns on Example 2 Temperature begins at 90 and rises to 150 see Figure 2B At 100 both stages are on This is the case when a boiler is first started and the controlling temperature is below the operating setpoint minus all of the differential setpoints At that time both stages are turned on in sequence from 1 to 2 At 130 stage 2 turns off At 140 both stages are off Example 3 Boiler is initially started and the controlling temperature is at 95 see Figure 2B Both stages will turn on in sequence from
51. sk should appear when the diode is connected and not when it is disconnected The CCB can be individually checked out by setting the 10 position CCB dipswitch to off This will make the system operate as a single stage and disable the other FCB s Watching the Control States screen while troubleshooting the heating sequence will help determine what is causing the problem Knowing what state the CCB and FCB s are in when the problem occurs will help to pinpoint a possible source of the fault Write down the proper positions of the dip switches after initial installation and compare them to the present dipswitch setting shown on the Configuration Settings screen This will catch any accidental changing of the dipswitches NEW BOILER LIMITED WARRANTY A O Smith Corporation the warrantor extends the following LIMITED WARRANTY to the owner of this hydronic boiler 1 within TEN years after initial installation of the boiler the heat exchanger shall prove upon examination by the warrantor to be defective in material or workmanship the warrantor at his option will exchange or repair such part or portion This term is reduced to FIVE years if this boiler is used for volume hot water supply purposes other than hydronic space heating a This warranty is extended to the owner for all other parts or portion during the FIRST year following initial installation of this boiler b The warranty on the repair or replacement of the part or
52. switch inputs and output states An asterisk is displayed next to the label when the status is True the description is fulfilled For example if water is flowing or detected by the flow sensor then an will appear in front of the Flow label i e Flow Another example would be the ECO switch If the outlet temperature is too high the display will show NOTE The LW CO IRI Gas Valve Powered Vent High Gas and Low Gas inputs are optional inputs Flame sensing Igniters and Blowers are optional on Stages 2 3 and 4 Except on a 4 stage system stage 2 always has an Igniter Blower and Flame Sensor Those dipswitches on stage 2 are not relevant One or two speed blowers can be used on any stage The System monitors the inputs at these times ECO LW CO Blocked Flue Low Gas Hi Limit and Hi Gas at all times for a fault condition Outlet temp exceeds High Limit setpoint Power Vent output relay activated Igniter current sufficient for ignition Input open open open closed open closed closed closed closed closed open Tstat at all times for open closed conditions RI Gas and Powered Vent for an on condition when their respective outputs Pump IRI Gas Pwr Powered Vent Power are turned on and an off condition at all other times Flow for an on condition when the pump is on no check for off state High Speed Blower Prover when the High Speed Blower is on L
53. tch 8 Spare Switch 9 amp 10 Number stages FCB s 9 10 stages Off 1 Off 2 NOTE If the unit power up with the number of stages selected by dip switches exceeding the number of FCBs the CCB will detect this condition and go into a hard lockout After changing the dip switches to the correct number of stages the power must be cycled on and off to accept the change Example of Dip Switch configuration ON GB model 3 ignition trials IRI Inlet control No Power Vent No LW CO T3 3 45 8 7 8 3 1 No Low Gas 1 stage CCB Three position Dipswitch Flame Control Section This dipswitch is similar to the FCB dipswitches described below but with only three switches being used the number of blower speeds switch 3 Hi Gas option switch 2 and a spare switch 1 Only the blower speed selection and Hi Gas are required because FCB1 always has a blower igniter flame checking and the address is always stage 1 FCB Eight position Dipswitch Switch 1 Spare Switch 2 Hi Gas On Yes Off 2 No Switch 3 Number of Blower Speeds 1 speed Off 2 2 speed Switch 4 Igniter used On Yes Off No Switch 5 Blower used On Yes Off 2 No Switch 6 Flame Checked On Yes Off No Switch 7 amp 8 Stage selection 7 8 Stage Off Off Not allowed On Off 2 When switch 5 is in off no blower position switch 3 blower speeds is ignored an Example of Dip Switch configuration Stage 2 1 blower sp
54. tlet and either inlet or tank is required The CCB accepts analog temperature inputs from up to three sensors inlet outlet and tank ECO input CCB required The ECO emergency cut out is a thermostat switch which is located inside the output probe It is a normally closed switch that opens if the probe is exposed to a temperature higher than the trip point Thermostat input CCB optional This input is set up to work with an externally connected thermostat that provides a contact closure If this input is g 6 B n n ais REM LOCH oe ESCH D 915 00 zc 3 9050 me RE Jg c9 t Bq eka zeha Lb sgu FA WEM ga 5 a vdl D o roe Ba 000 0 em riz SED OO Ra ea QU GO 5 eza ay g i n t L1 EP 5049 80 99 es B sg a g 0 651 eria c 91H 3 a age eig 052 0183 Gp Gi edd d 193 85 GECH og og oO Cela 25 GrcH opo 989 _ go PCM L1 S724 6029 ceo o9 QD 5 Th a cA 160 19 ae D Scu Secu 900 vela LVM 22 B sra n 00 B 0 65 62 ZN 1024 ps TU
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