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A.O. Smith VB/VW- 1000 User's Manual

1. 6 ass nores nete ent edis tnra 7 Inlet Water Considerations 7 reir e MEC RR ENTRO A E T 7 i r t 7 Liquefied Petroleum Gas Models 7 High Altitude Installations cessere 7 Field Installed Component c cc cccccccccssesseceecesescessessessessaaseeeeeeees 7 CONTROL COMPONENTS a Feu presens 8 Hi 952H cupm E 8 Hot Surface tnnt e t nn eh notet enn 8 Pressure Switches 8 Low Gas RR 8 Water Flow SWC uiui eite uui ua 8 Flame RR TET RNC 8 Water Temperature Limit Controls 9 ONOFF c c E 9 Circulating 4 Ec 9 Temperature Probes 9 Low Water Cutoff Optional 9 Pressure Relief Valve 9 A Lu
2. 44 Troubleshooting Gas Valve 45 WM i ME 45 PREVENTATIVE MAINTENANCE nnn 45 Relief Valve 46 Combustion Air Filter a a be eus 46 Blower Compartment a 46 Burner Maintenance 46 Condensate Removal System 46 Venting tis RN T T T 47 Heat Exchanger Preventative 47 GMT a u u rre ir hie Tende epa basznds hatc rtr pati Ra edad 47 Tube Cleaning Procedure Mechanical Removal of Deposits 47 Replacement Parts aa 47 a elpccc 48 LIMITED WARRANIY u UU 51 INTRODUCTION This design complies with the current edition of the ANSI 221 13 low pressure boiler standard Compliance under this standard implies that when the boiler underwent test the gas manifold and control assembly provided on the
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4. siio ud uei 10 Required Ability 10 LOG Ori ua 10 Panels and RR 10 Chemical Vapor acceso traen cha T Installhon Clearances I 11 E igs 11 Air Requirements ceca pnr tnra c eem tasa se eden eve npe 11 Unconfined 5 ROREM 11 Confined SDpac luu ha ketenac 11 Fresh Air Openings for Confined 1 Outdoor Air Through Two Openings 12 Outdoor Air Through One Opening 12 Outdoor Air Through Two Horizontal Ducts 12 Outdoor Air Through Two Vertical Ducts 12 Air From Other Indoor 5 13 Termination Clearances Sidewall Power Vent 14 Termination Clearances Sidewall Direct Vent 15 luz cr 16 Special Installation Considerations 16 Venting System Using AL 29 4C9
5. above the terminal within n 3 feet 91 cm above if within amp harisontal distance of 12 inches 30 cm 12 inches 30 cm mechanical air supply 6 feet 1 83 m 10 feet 3 m horizontally inlet 2 feet 61 cm from the center line of the terminal Clearance above Clearance to unventilated paved sidewalk or soffit 12 inches 30 cm 12 inches 30 cm paved driveway located 7 feet 2 13 m T 7 feet 2 13 m T on public property Clearance to outside under earner 2 feet 60 cm 2 feet 60 cm veranda porch deck 12 inches 30 cm 12 inches 30 cm t or balcony Clearance fo inside 8 ft 2 44 m 8 ft 2 44 m corner 1 In accordance with the current CSA B149 1 Natural Gas and Propane Installation Code 2 In accordance with the current ANSI Z223 1 NFPA 54 National Fuel Gas Code T A vent should not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings Permitted only if veranda porch deck or balcony is fully open on a minimum of two sides beneath the floor Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer s installation instructions 19 VENTING CAUTION Proper draft must be maintained to ensure correct operation of this unit A WARNING Fire and Breathing Hazard The instructions in this section on poem venting th
6. Low 24VAC Brown Out Reset Timeout Reset FCB Comm Timeout No Flow Blower Prov Stg Blocked Flue Blocked Inlet High Limit Low Water Low Gas Powered Accessory High Gas Stg Inlet Probe Outlet Probe Tank Probe Igniter Stg Igniter Pwr Stg Igniter Hdwr Stg TROUBLESHOOTING IGNITION SYSTEM Fault Messages and Lockout Status stage number 1 2 3 or 4 DESCRIPTION RED LED LOCKOUT Communications with UIM interrupted Continuous Auto Reset Check communication cable to UIM Try moving to other Internal Communications connector on MCB Also check the connectors where the cable is plugged in for best connecting wires Communications with FCB interrupted Continuous Auto Reset Same as above Also try swapping FCB and UIM communications cables Line voltage less than 90 vac Continuous Auto Reset Check incoming power line for loss of voltage May also be caused by a power line brown out momentary loss of voltage Voltage from transformer less than 18 vac Continuous Auto Reset Check transformer output Should be over 24vac May be caused by excessive current drain or a faulty transformer Indicates a brown out reset occurred None Caused by a momentary dip in voltage on the MCB 5vdc power bus Contact factory Not considered a serious problem if it only occurs on very rare occasions In
7. 16 General Exhaust Vent Installation Procedure 16 Connecting Vent to Boiler 16 Venting SuIpDDOriS 2 u du ash etai tua aiia siat 17 Vertical Installation Requirements 17 Horizontal Installtion Requirements 17 Direct Vent Installation Requirements 19 INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSE T IS 19 SYSTEM INSTALLATION nnne nnns 22 ANCE A MT 22 Hot Water Heating Hydronic Equipment 22 Internal enne nennen ens 23 Hot Water Supply Boiler System General Water Line Connections 23 Hard Water a nnns 23 Thermal Expansion Closed 23 Remote Probe Installation Procedure 23 Gas 24 Gas Supply Line Sizing 24 MINS u u
8. NF AEA AL 0080 9 009717 000082 000898 002296 000 YLO 0079 01 000021 1100991 000 tOr trS 008 098 009 272 c 000 922 3 18 18 19 3 19 000 000 209 009 19S 000 729 008079 009 212 792 008 928 008 706_ 009 620 002 LOC 000 287 000 781 c Hu nig 002 667_ 000S8S OOv ScZ 008090 L pu nig Lyi z ZZ oel se vz 12 ___002 ___ ac lG oc 8 02 00 GL lta zi ov vie oe 179 oz 01 _ seuoul 9215 edid 5 1 000 JO enjeA BuneeH M sec oyloed pue 5591 Jo ISd 0 O AA Ul pL JO SeunssaJg SEH MJ pue Ju f Lg u edig Ayloedeyg Ses euedoug se ueirjddy ses 104 ezis edid 7 000 009 rt 000 000 S 000 008 S 000 000 9 000 002 9 000 002 21000 00S 7 000 001 8 000 008 8 000 002 6 000 006 01 P00 008 ZL 000 008 SL 000 000 Z u nig 000 082 2 000 09 c 000 099 000 096 c 000 0Sc 000 000 002 2 000 006 21000 00 000 092 t 000 002 S 000 092 9 000 002 7 000 000 11 JU D L8 AKARAK AMAR AE AKAK AE NC 000 082 000 022 000 009 000 099 000 0S8 000 096 000 090 000 092 2 000 00t 2 1000 099 2 000 000 2 000 029 2 000 092 000 0029 Ju n Lg8 APARACAM na NF NK NK NAN N
9. gt symbol can be selected with this key If a setpoint configuration item is selected the gt will then flash slowly to indicate that the item has been selected The Up and Down keys are 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 or press Menu key to go to the menu screen Ifa 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
10. Temperature probes MCB outlet and either inlet or tank are required The MCB accepts analog temperature inputs from up to three sensors inlet outlet and tank MRHL Manual Reset HIGH LIMIT The MRHL is a hi limit switch located inside the outlet probe It is a normally closed switch that opens if the probe is exposed to a temperature higher than the trip point Once tripped the control system needs to be manually reset Thermostat input MCB optional This input is set up to work with an externally connected thermostat that provides a contact closure If this input is 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 itis 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 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 required temperature has been reached AIR PRESSURE SENSORS OPEN CONDITION INDICATES FAULT Blocked Inlet MCB required Normally closed switch that activates if the air inlet is blocked 3 4 or more during operation Blocked Flue MCB required Normally closed switch that opens if the flue becomes blocked during operation Blower Prover MCB
11. it is required that a system operating temperature controller field supplied be installed to regulate loop or system temperatures Two yellow wires are provided in the rear junction box for this connection Do not operate this boiler without system or operating control When operating the boiler with the tank probe the enable disable must be wired together Refer to the Connection Diagram see Figure 17 and to the Schematic Diagram see Figure 18 zorz ez L04 086 ka 000 921 2 000 008 2 000 092 8 000 092 6 o00 zsr 0t d00 zez tL 00 002 LL600 9 9 z i 00 822 2 000 22 SL 000 700 21 000 896 61 0 9 2 000 088 92 lhu nig 270 Hc Srel o s 069 2971 996 01 272 9cg z 920 5 Lg 009 9sc c ooo zze e 000 o00 zo9 v 000 070 s ooo zee slooo z47 s 000 780 9 000 802 9 000 0 72 o00 e9z 8 000 0SZ 6 looo zto zi ooo 091 4t lu J i MA 1 js mr dn tien ata ut iti b 008 666 1002 ZEL Z 000 OVE 2 000 729 2 000 988 2 000 Zr0 2 000 861 000 019 OOO0 2 O00 reL t 000 089 vr 002 67 S 0009879 000 828 6 pun eli eps t pr pts pcd te n n ucc or 000 8vrz L 000 92 000 287 OOZ Les L 000 v6Z 1002 06 L 000 820 2 000 v8 21002 L2 00809 000 voe z 000 zev 000 062 v 000919 8 282 GV M MA GG 1 1
12. 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 a pressure relief valve certified by C S A and approved by the American Society of Mechanical Engineers must have been installed and fresh water used for filling and make up purposes a This warranty shall apply only when the boiler is used 1 with inlet water temperature 120 F 49 C and above and outlet water 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 a non corrosive and non contaminated atmosphere b in the United States its territories or possessions and Canada 6 ata water velocity flow rate not exceeding or below the boiler s designed rates 7 indoor installation only b Any accident to the boiler any misuse abuse including freezing or alteration of it any operation of it in a modified form or any attempt to repair leaks in the heat exchanger 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 c
13. F 99 C a pressure rating not exceeding lowest rated working pressure of any system component and a discharge capacity exceeding total input of water boilers supplying water to storage tank Locate the T amp P relief valve a in the top of the tank or b in the side of the tank on a centerline within the upper 6 inches 152mm of the top of the tank see Figures 14 and 15 The tapping should be threaded in accordance with the current edition of the Standard for Pipe Threads General Purpose inch ANSI ASME B1 20 1 The location of or in tended location for the T amp P relief valve should be readily accessible for servicing or replacement VB HOT WATER HEATING BOILERS are shipped with a 50 psi 345kPa pressure relief valve This relief valve must be installed in the water outlet as near to the boiler as possible GENERAL REQUIRED ABILITY INSTALLATION OR SERVICE OF THIS BOILER REQUIRES ABILITY EQUIVALENT TO THAT OF ALICENSED TRADESMAN IN THE FIELD INVOLVED PLUMBING AIR SUPPLY VENTING GAS SUPPLY AND ELECTRICAL WORK ARE REQUIRED LOCATION When installing the boiler consideration must be given to proper location The location selected should provide adequate air supply and be as centralized with the piping system as possible CAUTION This boiler shouid not be installed on carpeting This boiler should not be located in an area where it may be subject to freezing This boiler must be located near a floor d
14. FIGURE 7 REMOTE PROBE INSTALLATION Temperature probes are 3 4 inch male NPT threaded immersion probes see Figure 7 Temperature probes have embedded temperature sensors thermistors The boiler s control system monitors these sensors to determine water temperature at various points in the system INLET AND OUTLET TEMPERATURE PROBES All VF boilers have one Inlet and one Outlet Temperature Probe factory installed in the top of the heat exchanger to monitor the water temperature entering and leaving the boiler The Inlet Probe is a temperature sensor only and has two leads The Outlet probe also contains the manual reset high temperature limit switch and has four leads The control system displays the Inlet and Outlet water temperatures sensed from these two probes on the default Temperatures screen REMOTE TEMPERATURE PROBE All VF boilers are supplied from the factory with a Remote Temperature Probe The supplied Remote Temperature Probe is used to control system water temperature for a single boiler in a domestic hot water storage tank or in the return line from a primary secondary hydronic heating system Use of the Remote Temperature Probe allows a boiler to sense the actual water temperature inside the storage tank or hydronic heating loop The boiler will modulate its firing rate in response to the actual system temperature and load conditions The control system displays the temperature sensed from the Remote Temperature Pr
15. U q 102 gt Z gt gt cu E E K SSYNLXIS OL 109 NMOHS 3ATVA JHL dO NI TIVLSNI GSYINDSY SI 3ATVA NMOG N3HM S3302 1V901 11 39NVQHOOOV NI TIVLSNI 3univuadW3l310W3H IWNOILIGGV HOS S3ONVNIQHO ANY 53800 W907 HLIM MO3HO jovo AMNLVYSdWSL ONILVINOMIO S3OIA3G H3HLO NOILVHOO9IJNOO ONIdid aalsaoofns SMOHS 9SNIAWCG SIHL IN 3ATVA 4373Y 3 unSS3ud Ye JATVA 431744 AYNIVYSAdWSL INO W31SAS AH3AOO3M TIV8 LHOd TINA C JYNSS3AYd 9 3snivesadiWa X4NVL 39VMHOLS 1VOILH3APH3TIOS 3NO 0001L 008 MA S 431108 JA IN393l MNVL IWOILYSA HLIM 331108 AlddNS LOH MA 133OW 26 S 38n9l3 8 318v1 335 JO 9215 OL LOH 303 edid 2 JO 129 06 Jo e 0 e JOU pue yue Buidid y 3A1VA Q1VOS LLNV NV aav LNdLNO eBesn eus sepoo joq 10 UMOUS 15008 NIVISO OL ulejs s ay ui jueuoduioo Aue Bues eunsseJd jou eys z l euynsseJd pue Z AMVSS3O3N SAYNLVYAdWAL
16. YILYM EN AlddNS W31SAS _ 3gosd asnivsadiWal ALOWSY HOLIVHVd3S NMOHS AATWA AHL dO SOV Id NI TIVLSNI GSYINDAY SI IMYA N3HM 58009 TVOO 1 TIY HLIM 3ONVQHOOOV NI TIVLSNI HO LIMS H31VM 3sunivsadiWal 310W3y SAIN3IN3SIQDO38 HOJ S3ONVNIQHO ANY 53809 TVOO 1 M23HO S3OIA3Q YSHLO ANY NOILVSHOOIJNOO S9NIdld qalsa99fns SMOHS SIHL NOILNVO A9VS SYN LWYAdWSL ONI1V 119319 JAYA 3 nSS3xd ANWA ON WALSAS SNIdld 3ATVA 33l 138 OINOHGAH AHVONOO3S ANVIWIHd 31108 000L 00S 8A JA LHOd TINA C AYNSSAYd 8 38niveadiwaL OIN393 oe o WY SNIdid ANHYONOO3S AYVINIYd IVOIdAL VL AYNSIS 8 318V1 335 sasniXIi3 OL aariddns S31vM JO ezis GIVOS INVNY GV indino waLsoog dd ou Zo Pe onasucn 02 otc e es t ti em NIVLBO OL AHVSSHOHN 33V S3f Vida Wal ul9js s y ui ue jo inss id p ox jou eus Huas joie oJnsseJd pue eJnjeJeduie oul Z JIV3H3 d dl San ixi3 LV 3sniveadiNal ASN i i f 34VS d332X3 GINOHS SNILL3S budd SALON d39NVG W NOILO3NNOO 074 Q3HSINIA NOISNVdX3 U IVA
17. area of the venting including but not limited to decks and porches the following requirements shall be satisfied _ INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled equipment the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back up is installed on the floor level where the gas equipment is to be installed In addition the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling building or structure served by the sidewall horizontal vented gas fueled equipment It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic the hard wired carbon monoxide detector with alarm and battery back up may be installed on the next adjacent floor level In the event that the requirements of this subdivision can not be met at the time of completion of installation the owner shall have a period of thirty 30 days to comply with the above requirements provided that during said thirty 30 day period a battery operated carbon monoxide detector with an alarm shall be installed APPROVED C
18. om above the metei 1 the meterke ulator g regulator assembly 9 assembly assembly Clearance to service regulator vent outlet 3 feet 91 cm 3 feet 91 cm 6 inches 15 cm for appliances up Clearance to a non to 10 000 Btu hr 3 kW 12 inches 4 feet 1 2 m below or to Clearance to mechanical air supply 30 for appliances between gic i BERING 1100 C permanently closed 12 inches 30 cm 12 inches 30 cm J inlet into building or 10 000 Btu hr 3 kW and 100 000 30 anm window combustion air inlet to Btu hr 30kW 36 inches 91cm p 9 u Clearance above grade veranda porch deck or 12 inches 30 cm 12 inches 30 cm balcony 6 inches 15 cm for appliances up to 10 000 Btu hr 3 kW 12 inches 30 4 feet 1 2 m below cm for appliances between 10 000 or to side of opening Btu hr 3 kW 100 000 Btu hr 30 1 foot 30 cm above kW 36 inches 91 cm for appliances opening above 100 000 Btu hr 30 kW Clearance to window or door that may be opened any other appliance for appliances above 100 000 Btu hr 30 kW Vertical clearance to ventilated soffit located above the terminal Clearance to a above within a horizontal 12 inches 30 cm 12 inches 30 cm mechanical air supply 6 feet 1 83 m 10 feet 3 m horizontally distance of 2 feet 61 inlet cm from the center line of the terminal Clearance to unventilated soffit emosi m 12 inches 30 cm Clearance above p
19. 22 1 ous m Minimum Pressures must be maintained during all operating conditions Electrical Power 120v 60hz and 30 amps TABLE 2 ROUGH IN DIMENSIONS Models VB VW 500 VB VW 750 VB VW 1000 Flue Outlet Diameter 152 152 Air Intake Diameter 102 102 2 NPT Water Outlet 2 NPT 1 N N N O oO NIN olo N N w o i olo N N w o II olo NIN 1143 1295 1499 1067 1219 16 5 11 5 10 5 CAPACITY AND FLOW DATA TABLE 3 RECOVERY CAPACITIES Input Output Temperature Rise F C joa Rating Rating E _ 20 60 100 120 140 Btu hr Btu hr 22 33 4 90 560 j 67 78 e vus zoo sa 1 268 362 1 371 543 2 056 TABLE 4 PUMPING PERFORMANCE GUIDE VB MODELS FLOW HEAD LOSS AND TEMPERATURE RISE 20F 11 C At 30F 17 C At 40F 22 C At Maximum Flow Rate Minimum Flow Rate verso z 22 oe 2 21 os se ra os nofe as ra 7 52 os 5 SAFE INSTALLATION AND SERVICE 2 GENERAL SANE Y uu p apnea tud es Feb ep 9 DIMENSION AND CAPACITY DATA 4 CAPACITY AND FLOW DATA eere 5 CONTENT ose M J 6
20. A O Smith dealers authorized servicers or distributors Refer to the Yellow Pages for where to call or contact in United States the A O Smith Water Products Company 500 Tennessee Waltz Parkway Ashland City TN 37015 1 800 433 2545 or in Canada A O Smith Enterprises Ltd 768 Erie Street Stratford Ontario Canada N5A 6T3 519 271 5800 When ordering parts be sure to state the quantity part number and description of the item including the complete model and serial number as it appears on the product Refer to the parts lists for more information For Technical Assistance call A O Smith Technical Information Center at 1 800 527 1953 48 49 50 LIMITED WARRANTY A O Smith Corporation the warrantor extends the following LIMITED WARRANTY to the owner of this boiler 1 If within TEN years after initial installation of the boiler a heat exchanger or gas burner shall prove upon examination by the warrantor to be defective in mate rial 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 water heating 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 portion will be limited to the unexpired term of the original warranty
21. Also check the gas inlet pressure Problem Gas OK no burner start up both shutoff valves are open fan turns There is not enough gas to accommodate a start up Turn throttle screw 75 turn counterclockwise and try to start again with more gas Problem Boiler makes noise at high CO level Premix boilers may have a loud whistle noise problem at high CO levels This can sometimes be alleviated by decreasing the CO level Problem Strong oscillations at burner start It is normal for a small oscillation to occur in the first second of the burner start If the oscillation is very strong or lasts very long decrease the resistance of the chimney by using a shorter tube with a larger diameter An additional solution is to change the start up power of the burner Problem Nominal power of the mixing unit is unattainable Possible causes for this issue are 1 the boiler and burner head pressure drop is too large 2 fan not turning at correct speed 3 sensing tube is clogged or broken Problem After some time the pressure regulation of the valve fails Dirt in the valve finer than 0 013 0 34mm can prevent the correct function of the servo pressure regulator Replace the valve and add a gas filter in front of the new valve This is a pre mix burner system The flame is not supposed to be directly on the burner The flame should be just above the burner deck approximately 1 8 and
22. E E E E u u sm E E DN UDIN 28 SUGGESTED PIPE SIZING TABLES 29 WIRING DIAGRAM pn prseter bu Pan rta Ret ener 30 VB VW 500 750 amp 1000 SCHEMATIC 32 OPERATION T T 39 WANS OCIA LLULLU RR C 33 AR RE 33 Filling and Purging of Heating Boiler Installation 33 Filling Hot Water Supply Boiler Installation 33 enmc M M 33 Inlet Gas Pressure aaa aaa 33 Water Temperature 34 LIGHTING amp OPERATION INSTRUCTIONS 36 MM 37 Setting of the Test Mode 37 Control i 37 inputs MOB 38 Operating 39 UIM Operating Procedures 40 Operating Setpoint Adjustment Procedure 41 High Limit Differential Setpoint Adjustment Procedure 42 TROUBLESHOOTING IGNITION SYSTEM
23. MODE Press select forthe desired option For checking the combustion setup on MIN or MAX the boiler will remain in this state for ten minutes before defaulting to the MOD modulation mode TABLE 11 HIGH FIRE SETTING NATURAL GAS 8 5 9 0 CO 9 5 10 5 PROPANE Set boiler to the Test Mode High as described above to achieve maximum firing rate of the boiler Check combustion readings using a combustion analyzer If combustion readings are not in accordance with the chart above adjust as follows remove the flat round blue plastic cap from the cover Using a 3mm 7 64 hex wrench turn the adjustment screw counterclockwise to increase or clockwise to decrease gas flow and achieve the desired CO level See Table referenced above for correct settings There will be a slight time delay between the adjustment and the response of the CO measuring instrument Adjust the settings in small increments and allow the combustion readings to stabilize before readjusting When desired adjustments are complete reinstall the blue plastic cap on the cover Combustion samples shall be taken within two feet of the boiler IMPROPER ADJUSTMENT CAN CAUSE INCOMPLETE COMBUSTION RESULTING IN DEATH 37 TABLE 12 LOW FIRE SETTING NATURAL 6 5 7 5 CO PROPANE 7 5 8 5 CO Set boiler to the Test Mode Low as described above to achieve minimum firing rate of the boiler Check combustion readings using a combustion
24. Note that areas of the drain line which include a sag or low spot in the line will also form a condensate trap which can be removed by levelling the tube and does not indicate a blocked system Inspect the metal vent drain and vent collector drain connectors at six month intervals Remove the hoses from the connections then check with a small wooden dowel or plastic rod passed up through the metal connection to insure the passage is clear using caution to not bend or damage the connector Call a qualified service agent to inspect and correct the problem if any obstructions are found in the connectors Replace all hoses and clamps immediately after inspection and before starting the boiler in accordance with the Lighting and Operating Instructions DO NOT OPERATE THE BOILER UNLESS ALL CONDENSATE DRAIN LINES ARE PROPERLY CONNECTED AND WORKING When a means to neutralize condensate has been installed you must also follow operating inspection and maintenance procedures specified by the manufacturer of the product Inspect the installed device to insure that it does not cause condensate to remain in the boiler or vent for any reason VENTING MAINTENANCE It is recommended that the intake and exhaust piping of the appliance be checked every 6 months for dust condensate leakage deterioration and carbon deposits A WARNING Do not use brush or other static creating material to clean dust and carbon deposits from heating surfac
25. Relief Valve operation water discharged from the valve due to excessive pressure build up This condition is not covered under the limited warranty The Temperature Pressure Relief Valve is not intended for the constant relief of thermal expansion A properly sized thermal expansion tank must be installed on all closed systems to control the harmful effects of thermal expansion Contact a local plumbing service agency to have a thermal expansion tank installed REMOTE PROBE INSTALLATION PROCEDURE A remote probe is supplied with each hot water supply boiler VW models To connect the remote probe to the boiler remove the cover from the junction box at the rear of the unit Connect the probe wire pigtails see Figure 7 Check the field connection diagram located on this cover of the junction box to assure proper wiring Once the remote probe has been connected to the boiler it must be designated as the controlling probe for the system This is accomplished by changing two dipswitch settings on the MCB First dipswitch 4 must be set to the ON position to designate the remote probe as the controlling probe Second dipswitch 1 must be set to the OFF position to limit the maximum remote probe temperature for VW applications Also make sure dipswitch 1 is set to the OFF position which sets the outlet temperature for VW applications Failure to do this will void the warranty If the remote probe is not designated as the control
26. TERMINATION TWT 18 DIRECT VENT INSTALLATION REQUIREMENTS Follow the guidelines in the HORIZONTAL INSTALLATION REQUIREMENTS section for the exhausting of flue products IMPORTANT The labels in the Direct Vent Kit must be affixed to the boiler in locations specified by the instruction sheet provided in the kit The following are requirements for the Air Intake Terminal AIT 1 3 The Air Intake System AIS must terminate with the venting equipment provided with the boiler Refer to the parts list for required direct vent parts he AIT shall not be located less than 3 feet 1 0m below any exhaust vent within 10 feet 3 0m see HORIZONTAL INSTALLATION REQUIREMENTS section The total horizontal distance of the AIS from the boiler s Blower Adapter to the outside of the AIT shall not be greater than 70 equivalent feet 21 3m of vent pipe nor less than 3 feet 1 0m excluding eloows Amaximum of 3 elbows equivalent to 10 feet 3 0m each of pipe may be used INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS For all side wall terminated horizontally vented power vent direct vent and power direct vent gas fueled water heaters installed in every dwelling building or structure used in whole or in part for residential purposes including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven 7 feet above finished grade in the
27. TWT Plan the terminal location based on the dimensions shown in Figure 9 Do not locate the terminal within 8 feet 2 5m of an inside corner of a building or adjacent to outside walls shrubs or other such objects that may cause adverse wind conditions in the immediate area The TWT shall be located not less than 12 inches 305mm above grade or in geographical areas where snow accumulates no less than 12 inches 305mm above the anticipated snow line Ensure that the TWT is protected against blockage which may occur during ice buildup or snowstorms The TWT shall terminate at least 3 feet 1 0m above any forced air inlet within 10 feet 3 0m except when the forced air inlet is the combustion air intake of a direct vent appliance The TWT shall terminate at least 4 feet 1 2m below 4 feet 1 2m horizontally from or 1 foot 305mm above any door window or gravity air inlet into any building as provided in the current edition of the NATIONAL FUEL GAS CODE ANSI Z223 1 see Figure 9 In addition a minimum clearance of 4 feet 1 2m hori zontally from and in NO CASE ABOVE OR BELOW unless the 4 feet 1 2m of horizontal distance is main tained from electric meters gas meters regulators and relief equipment This horizontal exhaust vent system must pitch upward toward the termination at 1 4 inch per foot 21mm per meter The TWT is designed such that the building is protected from degradation by flue gas and condensat
28. The User Interface Module UIM communicates with the user through a set of touch pads and a 4 line 20 character LCD display The PDB provides connection points for input power the water pump and the transformer It also distributes power to the system and contains the system fuses The MCB also contains an external communications system to allow for connection to a PC a modem an EMS system or something similar 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 boards These 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 service light as well as indicate the cause of the error on the display The operating programs for the system are stored in permanent memory inside the microcontrollers User selectable operating parameters and a history of detected faults are stored in rewritable memory in the microcontrollers A loss of power does not affect either of the memories INPUTS TO MCB TEMPERATURE SENSORS
29. 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 a hot water tap or to draw their own bath water Never leave a child or disabled person unattended in a bathtub or shower 34 The boiler should be located in an area that is inaccessible to the general public Never allow small children to use a hot water tap or to draw their own bath water Never leave a child or handicapped person unat tended in a bathtub or shower TABLE 8 Risk of Scalds Water Temperature Time to Produce 2nd amp 3rd Degree p Burns on Adult Skin Over 170 F 77 C Nearly instantaneous 160 71 About 1 2 second SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF TURN OFF THE MAIN MANUAL GAS SHUTOFF VALVE TO THE APPLIANCE The operating temperature of the boiler must be maintained as follows 120 F 49 C or higher inlet water temperature to the boiler e 20 F 11 C differential between the boiler s inlet and outlet e g 120 F 49 C inlet 140 F 60 C outlet minimum design temperatures If the inlet water temperature into the boiler is less than 120 F 49 C adjustments on the water bypass and the outlet valves at the rear of the boiler see Figures 14 and 15 are required wait at least one minute between adjustments for the temperature to stabilize 1 If necessary throttle down close the water outle
30. analyzer If combustion readings are not in accordance with the chart shown above adjust as follows remove the cap on the gas regulator using a slotted screwdriver This will expose the offset adjustment screw Using a TORX T40 or a 5mm hex wrench carefully adjust the low fire gas setting to achieve the CO level prescribed in above reference table Note The rotation of the Low Fire adjustment is opposite of the High Fire as follows Clockwise rotation increases gas flow counterclockwise rotation decreases gas flow Adjustments to the offset pressure regulators should not exceed 1 4 turn at a time before allowing the readings to respond and stabilize After proper low fire offset adjustment is made reinstall the slotted cap on the regulator Following all gas valve adjustments check for proper light off and verify correct fuel air mix and combustion quality throughout the entire firing range from lowest to highest fan speed CONTROL SYSTEM The EMC modulation 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 Modulation Control Board MCB see Figure 2 Power Distribution Board PDB see Figure 2 User Interface Module UIM see Figure 20 The MCB contains circuitry for both master control and flame control Dip switches on the MCB are used to configure the system
31. and in fault mode the monitors the signals and the internal operation for faults Any current error screen is displayed detected fault will halt the heating sequence and shift the system to the service mode where the detected fault will be displayed 4 The system then compares the temperature read from the controlling probe inlet or tank to the setpoint temperature If TEMPERATURE SETPOINTS SYSTEM CONTROL ALGORITHM 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 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 It will stop heating the water when the 5 The heating sequence begins by applying power to the pump temperature rises to the operating setpoint 39 UIM OPERATING PROCEDURES 25 100 FIRING FIGURE 20 USER INTERFACE MODULE 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
32. boiler met safe lighting and other performance criteria Detailed installation diagrams are found in this manual These diagrams will serve to provide the installer a reference for the materials and methods of piping necessary It is essential that all water gas piping and wiring be installed as shown on the diagrams You should thoroughly read and understand this manual before installation and or operation of this boiler The factory warranty will be void if the boiler s have been improperly installed or operated AL 29 4C is a registered trademark of Allegheny Ludlum Corporation In addition to these instructions the boiler s shall be installed in accordance with those installation regulations in force in the local area where the installation is to be made These shall be carefully followed in all cases Authorities having jurisdiction should be consulted before installations are made In the absence of local codes the installation must comply with the current editions as follows In the United States The National Fuel Gas Code ANSI Z223 1 NFPA 54 and the National Electric Code NFPA 70 GROUNDING INSTRUCTIONS This boiler must be grounded in accordance with the National Electrical Code and or local codes Boiler is polarity sensitive correct wiring is imperative for proper operation This boiler must be connected to a grounded metal permanent wiring system or an equipment grounding conductor must be run with the c
33. fs Smith GAS FIRED COPPER BOILERS FOR HYDRONIC HEATING AND HOT WATER SUPPLY INSTRUCTION MANUAL Installation MODELS Operation VB VW 500 750 AND 1000 Maintenance SERIES 200 201 Limited Warranty T Ee CERTIFIED www ahridirectory org 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 Donottouch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions f you cannotreach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier A WARNING Read and understand this manual cam and all Warnings and Cautions within before installing and using this appliance Place these instructions adjacent MC BEE SC RENTON WA to boiler and notify owner to keep STRATFORD ONTARIO VELDHOVEN THE NETHERLANDS for future reference NANJING CHINA www hotwater com email parts hotwater com PRINTED 0911 320856 001 SAFE INSTALLATION USE AND SERVICE The proper installat
34. inches 15 cm 6 inches 15 cm for appliances ps DEOR GU up to 10 000 Btu hr 3 kW 12 9 aches 23 for Clearance to window or I es 30 cm tor appliances appliances between Clearance to service between 10 000 Btu hr 3 kW 3 feet 91 cm 3 feet 91 cm door that may be opened 10 000 Btu hr 3 kW regulator vent outlet and 100 000 Btu hr 30 kW 36 and 50 000 Btu hr 15 inches 91 cm for appliances kW 12 inches 30 cm above 100 000 Btu hr 30 kW E for appliances above 50 000 Btu hr 15 kW 6 inches 15 cm for 6 inches 15 cm for appliances up Clearance to a non to 10 000 Btu hr 3 kW 12 inches 2PPliances up to 10 000 Btu hr 3 kW 9 inches 23 Clearance to mechanical air supply 30 cm for appliances between C cm for appliances between Clearance above grade veranda porch deck or 12 inches 30 12 inches 30 cm balcony 3 feet 91 cm within a height 15 3 feet 91 cm within a height feet 4 5 m above the meter 15 feet 4 5 m above the regulator assembly meter regulator assembly permanently closed 6 inches 15 cm 6 inches 15 cm inlet into building or 10 000 Btu hr 3 kW and 100 000 window combustion air inlet to Btu hr 30 kW 36 inches 91 cm 19 000 Btu hr 3 KW and 50 000 Btu hr 15 kW 12 any other appliance for appliances above 100 000 Btu inches 30 cm for appliances hr 30 kW above 50 000 Btu hr 15 kW Vertical clearance to ventilated soffit located
35. levels of carbon monoxide gas in excess of the safe limits which could result in serious personal injury or death Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual Rated inputs are suitable up to 7000 feet 2134m elevation Consult the factory for installation at altitudes over 7000 feet 2134m FIELD INSTALLED COMPONENTS When installing the boiler the following components MUST be installed 1 Circulating Pump Hydronic 2 Tank Temperature Control Probe Hot Water Supply 3 Remote Temperature Control Probe Hydronic 4 Storage Tank T amp P Relief Valve 5 Manual Gas Shutoff Valve Supply Check the FEATURES AND CONTROLS section for further information CONTROL COMPONENTS THE CONTROL SYSTEM The control system consists of four basic components 1 Modulation Control Board MCB 2 Power Distribution Board PDB 3 Variable Frequency Drive VFD see Figure 2 User Interface Module see Figure 20 The Modulation Control Board and the Power Distribution Board are located in the control box and can be accessed by opening the front door of the unit The User Interface Module is attached to the front door panel Every system will have one Modulation Control Board MCB one Power Distribution Board PDB and one User Interface Module UIM The MCB contains dipswitches which are used to configure the boiler for several different control options see the C
36. lock out In the event of a lockout depress the SELECT button on the display board to restart the boiler WATER TEMPERATURE LIMIT CONTROLS CAUTION Limit controls are safety devices and are NOT to be used as an operating device thermostat The V B W models incorporate an outlet water probe consisting of two limit controls 1 Reset High limit control that can be set as high as either 210 F 99 C or 235 F 113 C depending on the application 2 A fixed manual high limit factory set at 244 F 118 C If the manual reset should open due to high temperature the gas valves will close and unit will go into lockout If lockout occurs push the SELECTION button on UIM to restart boiler ON OFF SWITCH The ON OFF Switch is a single pole single throw rocker switch This switch provides 120V from the line source to the boiler CIRCULATING PUMP HOT WATER SUPPLY BOILER VW the circulating pump is integral to the VW models This pump has been lubricated at the factory and future lubrication should be in accordance with the motor manufacturer s instructions provided as a supplement to this manual HOT WATER HEATING BOILERS VB the circulating pump is NOT provided on standard models optional and must be obtained and installed in the field NOTE If a system pump is to be installed on a VB model the maximum rating of pump motor must not exceed 1 hp TEMPERATURE PROBES TEMPERATURE PROBE
37. of foreign matter Clean burner with vacuum cleaner DO NOT distort burner ports Reinstall burners in unit Ensure that all the screws on the burner flange are tightened securely so that the gasket will provide a good seal Also check for good flow of combustion and ventilating air to the unit 1 2 3 4 5 After placing the boiler in operation check the ignition system safety shut off devices for proper operation To accomplish this with the main burner operating close the valve on the manifold Within four seconds the main burners should extinguish If this does not occur immediately discontinue gas supply by closing main manual shut off and call a qualified service agent to correct the situation If the burners extinguish then light boiler in accordance with lighting and operating instructions A WARNING The flow of combustion air to the boiler must not be obstructed The boiler area must be kept clear and free from combustible materials gasoline and other flammable vapors and liquids Any safety devices including low water cutoffs used in conjunction with this boiler should receive periodic every six months inspection to assure proper operation Alow water cutoff device of the float type should be flushed every six months Periodic checks at least twice a year should be made for water leaks More frequent inspections may be necessary depending on water conditions The boiler mounted gas and electrical contr
38. 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 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 e Heat Stage The system will command the FCB micros to start their heat sequence 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 e Soft Fault State See Fault Description section for list of soft and Auto Reset faults The pump remains on for the selected post circulate time to cycle the hot water out of the boiler The FCB is commanded to shut down and the Alarm output is turned on The green LED turns off and the red Service turns on The MCB remains in this state until one of the following occurs One hour passes automatic restart after one hour f Communications error system will automatically restart if communications re establishes f user presses Select key while current error screen is displayed Hard reset If high limit error the outle
39. required Normally open switch that closes when the air pressure produced by the blower is above the set point GAS PRESSURE SENSORS OPEN CONDITION INDICATES FAULT Low Gas MCB required Normally open switch that closes when the gas pressure rises above the trip level This input is enabled disabled by a dip switch on the MCB Hi Gas MCB required Normally closed switch that opens if the gas pressure exceeds a set value This input is enabled disabled by a dip switch on the MCB WATER LEVEL SENSOR OPEN CONDITION INDICATES FAULT Low Water Cut Off MCB optional Normally open switch that closes when water reaches preset level This input is enabled disabled by a dip switch on the MCB WATER FLOW SENSOR Flow MCB required Normally open switch that closes when flow exceeds a set value MCB Ten Position Dipswitch FLAME SENSOR Flame MCB required Returns a signal to the microprocessor if flame is detected on the burner If the flame rod is missing or shorted the flame will not be detected OUTPUTS FROM MCB RELAY CONTACT OUTPUT Alarm MCB 24VAC optional Provides electrical power to operate an external alarm This can be an audio device i e Sonalert a visual device lamp or any other device that will operate with the voltage and current level provided Pump MCB 120VAC required on systems that do not have an external pump Provides electrical power to directly operate a pump or
40. 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 The operation of these parts is described in the following section 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 is 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 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 7
41. the MCB 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 shorted or open Flashing HARD 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 MCB 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 Remote probe shorted or open Flashing HARD 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 MCB 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 current is too low Flashing HARD Caused by a low current draw problem with the 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 igniterto get hot enough to fire the gas properly Check the igniter and its associated wiring Improper power applied to the igniter circ
42. the unit A 24VAC thermostat aquastat can only be used as an On Off switch for the unit The actual controlling of the phasing will be through either the inlet or remote probe To use a 24VAC system controller dipswitch 4 on the MCB must be switched to the on position see REMOTE PROBE INSTALLATION INTERNAL CONTAMINANTS The hydronic system must be internally cleaned and flushed after a new or replacement boiler has been installed to remove contaminants that may have accumulated during installation This is extremely important when a replacement boiler is installed into an existing system where Stop Leak or other boiler additives have been used Failure to clean and flush the system can produce acid concentrations that become corrosive and leads to heat exchanger failure All hot water heating systems should be completely flushed with a grease removing solution to assure trouble free opera tion Pipe joint compounds soldering paste grease on tubing and pipe all tend to contaminate a system Failure to flush contaminants from a system can cause solids to form on the inside of boiler exchangers create excessive blockage of water circulation deterioration of the pumps seal and impellers 23 HOT WATER SUPPLY BOILER SYSTEM GENERAL WATER LINE CONNECTIONS This section provides detailed installation diagrams for a typical method of application for the unit Piping diagrams will serve to provide the installer with a refer
43. 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 ECO The System monitors the inputs of these times MRHL Blocked Inlet Blocked Flue Low Gas Hi Limit and Hi Gas at all times for a fault condition e stat at all times for open closed conditions Flow for an on condition when the pump is on no check for off state Blower Prover when the Blower is on gniter 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 status that the MCB micros are in The MCB has 5 possible states and the FCB have 9 The normal MCB states sequence is to move from Idle to Pre Circulate when a call for heat is initiated Once heat has been satisfied or the Thermostat 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 MCB control states e Idle The yellow Standby LED is turned on and the system waits for a heat request determined by the Thermostat or controlling
44. ARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI UL 2034 listed and CSA certified SIGNAGE A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless upon inspection the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5 08 2 a 1 through 4 EXEMPTIONS The following equipment is exempt from 248 CMR 5 08 2 a 1 through 4 1 The equipment listed in Chapter 10 entitled Equipment Not Required To Be Vented in the most current edition of NFPA 54 as adopted by the Board and 2 Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling building or structure used in whole or in part for residential purposes MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM PROVIDED When the manufacturer of Product Approved side wall horizontall
45. BLES POSITION OFF FUNCTION 1 SPARE 2 YES HIGH GAS SWITCH 3 1 2 BLOWER SPEEDS 2 3 5 MCB DIP SWITCH Sw2 FUNCTIONS POSITION ON OFF FUNCTION 1 VB vw TYPE OF BOILER 2 3 1 IGNITION TRAILS WIRING LEGEND 3 IRI GAS VALVE 4 TANK INLET CONTROLLING PROBE 5 YES NO POWERED VENT 6 YES NO LOW WATER CUTOFF 7 YES NO FIRING TYPE SEE NOTES 8 MODULATION MULTI STAGE 9 NOT USED 120 VAC WIRING 10 NOT USED LOW VOLTAGE WIRING COMMUNICATION CABLES 227777777 C C 7 7 1 BK BLOWER NOTE DRIVE x IF ANY OF THE ORIGINAL WIRE SUPPLIED WITH THE APPLIANCE MUST BE REPLACED EQUIVALENT GAGE WIRE INSULATION TYPE 105 DEG C 600 VOLTS MUST BE USED CONNECT VB VW 500 750 amp 1000 SCHEMATIC DIAGRAM 120VAC HOT NEUTRAL PUMP RELAY CONTACTS CIRCULATING PUMP VW UNITS ONLY VW UNITS ONLY G ON OFF SWITCH GROUND 20 AMP FUSE PDB F2 ADDITIONAL GAS VALVE v ADDITIONAL RELAY OPTIONAL OE CONTACTS OPTIONAL VW UNITS ONLY 15 AMP FUSE PDB F7 l K8 ADDITIONAL RELAY OIL OPTIONAL K9 MCB IGNITER VFD MOTOR EGER VFD MOTOR DRIVE DRIVE CONTROL RPM 3 AMP FUSE PDB F3 PRIMARY SENSOR 7 5 AMP FUSE MCB SECONDARY K6 RELAY COIL MCB 24VDC GENERATION eB GAS VALVE MANUAL ECO K6 K4 K5 FLOW SWITCH MCB MCB MCB VFD MOTOR MS DRIVE CONTROL BLOCKED FLUE MICRO PROCESSOR y FLAME EXTERNAL ENABLE SENSOR RPM BLOWER PROVER SENSOR CN BLOCKED INLET PRO
46. CONDENSATE TUBING VENT TRAP LOOP VENT TRAP Loop DRAIN COMBUSTIBLE BOILER I FLOORING Foy Figure 10 VENTING SUPPORTS Care must be taken in the installation of the venting system that adequate support is maintained throughout the installation process When extending more than 10 feet 3 0m vertically vertical support kits are required once every 10 feet 3 0m of vertical run Vertical support is also required immediately after any transition elbow tee etc to vertical of over 10 feet 3 0m of run and after any offset in the vertical run The support brackets supplied in the Vertical Support Kit are to be securely fastened to a solid vertical member of the building using the appropriate fasteners i e wood screws for wood framing machine or tapping screws for structural steel or masonry anchors for solid masonry The bracket should be located so that it will not interfere with any joints of the venting system The bottom most support bracket should be located directly above the first transition from horizontal to vertical see Figure 10 Refer to Figures 12 12A 12B and 12C If a means of support for the brackets are not available and horizontal vent sections are present install hanger straps made from non combustible material as close to the points of transition as possible If the horizontal portions of the vent and or vent connector are longer than 6 feet 2 0m then install hanger straps every 6 feet 2 0m t
47. E TO COMBUSTIBLES OF 4 102mm DOUBLE WALL AL 29 4C VENT 6 152mm SINGLE WALL AL 29 4C VENT UPWARD SLOPE OF 1 4 PER FOOT 21mm PER METER NOTE Joints are not joined to show vent pipe orientation AL 29 4 INLET AND OUTLET OF THE BOILER BOILER AND BOOT TEE CONDENSATE TUBING BOILER TRAP LOOP er 6 INCH 7 j lt amp TEE DRAIN COVER A 70 EQUIVALENT FEET 21 3 M OF VENTING MAX 90 ELBOW 10 3 0 M 45 ELBOW 5 1 5 M BOOT TEE 5 1 5 M 4 INCH PVC PIPE ONLY 70 EQUIVALENT FEET MAX 27 4 M DIRECT VENT ONLY C ty XTERIOR WALL PVC COUPLING S IF NECESSARY 3 MIN 1 0 M JSSEEFSESEFEEESENEF m AIR INTAKE TERMINAL DIRECT VENT ONLY COMBUSTIBLE WALL COMBUSTION AIR FROM OUTSIDE SUPPORT VENT AT THIS TRANSITION POINT MAINTAIN MINIMUM CLEARANCE TO COMBUSTIBLES OF 4 102mm DOUBLE WALL AL 29 4C VENT 6 152mm SINGLE WALL AL 29 4C VENT lt a BOOT TEE A CAUTION Direct venting into dead air spaces such as alleys atriums and inside corners can cause recirculation of flue gases Recirculation of flue gases will cause sooting premature failure of the heat exchanger and icing of the combustion air intake during severe cold weather To prevent the ROOF JACK ASSEMBLY BOILER lt UONDEUSATE recirculation of flue gases maintain
48. ED and yellow standby LEDs come on next the service and runnings LEDs blink ON and OFF 10 The boiler will remain running until the set point is satisfied Once satisfied the blower will continue for 15 second post Stored values are recalled from memory purge period Configuration dipswitches are read 11 Once set point has have been satisfied the boiler pump will continue to run for the programmed post circulate cycle e Pending faults are recalled 12 The control now enters the idle state as displayed by the Micros on all boards start running indicated by a flashing Standby LED The control will continue to monitor heat Yellow LED near each micro demand and state of other system devices Upon a drop of Input sensors are read water temperature below the set parameters the control will E return to step 5 and repeat entire operating cycle Note 3 After initialization is complete approximately 10 seconds Any fault detection during standby or running modes will halt the system turns the green LED off and goes to the standby the heating sequence and shift the system to the service mode mode yellow Standby LED on unless a previously stored where the detected fault will be displayed fault has been recalled which will send the system into the l service model red Service LED on In standby mode the NOTE In standby and running modes the system constantly display shows the temperature screen
49. EVEL 4 INCH PVC PIPE ONLY 70 EQUIVALENT FEET MAX 27 4 M DIRECT VENT ONLY 70 EQUIVALENT FEET 27 4m OF VENTING MAX AL 29 4C AL 29C NOTES IF THE EXHAUST VENT TERMINAL IS WITHIN 10 3 0m OF A WALL OR A PARAPET IT MIUST EXTEND A MINIMUM OF 2 0 6m ABOVE THE WALL OR PARAPET ON SIDEWALL VENT INSTALLATION REFER TO FIGURE 9G FOR SPACING SPECIFICATIONS FOREXHAUST AND AIR INTAKE PIPE INSTALLATIONS 7 CLEARANCES SUPPORT ETC REFER TO FIGURES 12 AND 12A FIGURE 12C DIRECT VENT USING TWT WITH VERTICAL INTAKE 21 SYSTEM INSTALLATION GENERAL If the system is to be filled with water for testing or other purposes during cold weather and before actual operation care must be taken to prevent a downdraft entering the boiler or freezing air from contacting the system Failure to do so may cause the water in the system to freeze with resulting damage to the system DAMAGE DUE TO FREEZING IS NOT COVERED BY THE WARRANT Y Good practice requires that all heavy piping etc be supported Figure 13 shows a typical primary secondary piping method This is the preferred piping method for most copper fin tube boilers Other piping methods however may provide good system operation A prime concern when designing heating systems is the maintenance of proper flow through the unit during boiler operation The secondary pump should be sized per the recommended flow rate of the boiler see Dimension
50. G CONTROL BOARD MCB m GAS SWITCH RETURN LOW WATER LOW GAS POWER CUT OFF SW BK W u LOW GAS RETURN POWER VENTER AUDIBLE BLOCKED FLUE POWER ALARM BLOCKED BLOCKED FLUE RETURN h ON J5 FLUE SW FLOW SWITCH POWER FLOW SWITCH RETURN N a IRI GAS PROVER SW INLET INLET TEMPERATURE PROBE POWER BL LOW GAS TEMPERATURE INLET TEMPERATURE PROBE RETURN BL PROBE J8 x EXAMPLE 3 ON OFF INPUT SW MANUAL ECO POWER R OPTIONAL EQYIPMENT OUTLET MANUAL ECO RETURN R OUTLET TEMPERATURE PROBE POWER BK PROBE ECO OUTLET TEMPERATURE PROBE RETURN BK F1 CIRCUIT 7 5 AMP DEDICATED SINGLE PHASE 115VAC RMS INPUT WITH A GROUNDED NEUTRAL LINE PER NEMA STANDARDS USING A 20 AMP CIRCUIT BREAKER FOR FIELD WIRED CONNECTIONS USE NO 10 AWG WIRES RATED FOR AT LEAST 194 DEG F 90 DEG 1 2 3 4 5 N C 6 7 8 EXTERNAL JUNCTION BOX POWER An OUTSIDE CABINET PUMP RELAY RETURN PUMP RELAY POWER PUMP CONTACT RELAY ON OFF MAIN POWER SWITCH IRI GAS VALVE RELAY POWER OPTIONAL IRI GAS VALVE RELAY RETURN OPTIONAL 24VAC POWER 120VAC HOT IRI GAS VALVE CONNECTOR RELAY OPTIONAL 24VAC RETURN GROUND 24VAC RET 24VAC HOT 24VAC RET TB1 4 TB1 3 TB1 2 TB1 1 J1 o
51. NG 70 EQUIVALENT FEET wa CLEARANCE MAX 27 4 M DIRECT VENT ONLY ALL AROUND SUPPORT AS A NECESSARY FLEXIBLE COUPLING DIRECT VENT ONLY SUPPORT VENT AT THIS OUTLET OF THE BOILER TRANSITION POINT COMBUSTIBLE BOILER VENT 3 MAX WALL BETWEEN h BOILER AND MAINTAIN MIN CLEARANCE BOOT TEE TO COMBUSTIBLES OF 4 102mm DBL WALL AL 29 4C VENT 6 152mm SGL WALL AL 29 4C VENT BOOT TEE x BOOT TEE DRAIN COVER TRAP LOOP BOILER E FLOORING DRAIN d TEE CONDENSATE TRAP LOOP TUBING VENT VENT FIGURE 12A DIRECT VENT VERTICAL 20 Option B Figures 128 4 120 R 70 EQUIVALENT FEET 27 4m assures no recirculation of flue gases OF VENTING MAX AL 29 4C AIR INTAKE TERMINAL HORIZONTAL AIR INTAKE BO M Haa BETWEEN BOILER AND 5 x BOOT PVC PIPE 70 IF THE EXHAUST VENT TERMINAL IS WITHIN 10 3 0m EQUIVALENT FEET 27 4m OF A WALL OR A PARAPET IT MIUST EXTEND A MINIMUM OF 2 0 6m ABOVE THE WALL OR PARAPET 6 A Ll D 1 ee Oe ON SIDEWALL VENT INSTALLATION REFER TO FIGURE 9F FOR SPACING SPECIFICATIONS FOR EXHAUST AND AIR INTAKE PIPE INSTALLATIONS CLEARANCES SUPPORT ETC REFER TO FIGURES 12 AND 12A DRAIN FIGURE 128 DIRECT VENT VERTICAL VENT TERMINATION WITH HORIZONTAL INTAKE VERTICAL AIR INTAKE MUST BE 12 305mm ABOVE ANTICIPATED SNOW L
52. OB 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 DO 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 WATER DONOT OPERATE APPLIANCE UNLESS UNIT IS FILLED WITH WATER AND WATER LINES ARE FULLY OPEN 6 OPEN MAIN VALVE TURN MAIN GAS VALVE TO ON OR OPEN POSITION THE VALVE IS IN THE ON POSITION WHEN THE HANDLE IS PARALLEL TO THE GAS FLOW DIRECTION THIS APPLIANCE IS EQUIPPED WITH AN IGNITION DEVICE WHICH AUTOMATICALLY LIGHTS THE BURNER DO NOT TRY TO LIGHT THE BURNER BY HAND TURN ON POWER TO THE APPLIANCE SET SYSTEM TEMPERATURE CONTROLLER TO DESIRED OPERATING TEMPERATURE IF THE APPLIANCE WILL NOT OPERATE FOLLOW THE INSTRUCTIONS TO TURN OFF GAS TO APPLIANCE CALL YOUR SERVICE TECHNICIAN OR GAS SUPPLIER TO TURN OFF GAS TO APPLIANCE SET SYSTEM TEMPERATURE CONTROLLER TO LOWEST C SETTING TURN OFF ELECTRICAL POWER TO BOILER 36 CLOSE MAIN VALVE TURN MAIN MANUAL GAS VALVE TO OFF OR CLOSED POSITION THE VALVE IS IN THE OFF POSITION WHEN THE HANDLE IS PERPENDICULAR TO THE GAS FLOW DIRECTION ADJUSTMENT A WARNING 4 Failure to make accurate adjustments could cause improper combustion resulting i
53. S TRANSITION POINT COMBUSTIBLE WALL MAINTAIN MINIMUM CLEARANCE TO COMBUSTIBLES OF BOILER 6 INCH w 4 102 MM DOUBLE WALL AL 29 4C VENT prot 6 152 MM SINGLE WALL AL 29 4C VENT d a n a al LL Ms ax L BOOT TEE DRAIN COVER TRAP LOOP COMBUSTIBLE oom C E CONDENSATE TUBING VENT DRAIN TRAP LOOP VENT FIGURE 11 VERTICAL TERMINATION MAINTAIN MINIMUM CLEARANCE TO COMBUSTIBLES OF 4 102mm DOUBLE WALL AL 29 4C VENT 6 152 mm SINGLE WALL AL 29 4C VENT NOTES Joints are not joined to show vent pipe orientation ew 100 EQUIVALENT E FEET 54 9M MAX 90 ELBOW 10 3 0 M 45 ELBOW 5 1 5 M INLET AND BOOT TEE 5 1 5 M OUTLET OF a THE BOILER D Bs L d BOILER VENT 3 BETWEEN BOILER AND BOOT TEE N CONDE TRAP LOOP VENT SUPPORT VENT AT THIS TRANSITION POINT INTERIOR 6 2 0 HANGER STRAPS WALL THROUGH THE WALL TERMINAL UPWARD SLOPE OF 1 4 PER FOOT 21mmPER METER v EXTERIOR WALL COMBUSTIBLE WALL MAINTAIN MINIMUM CLEARANCE TO COMBUSTIBLES OF 4 102mm DOUBLE WALL AL 29 4C VENT 6 152mm SINGLE WALL AL 29 4C VENT 44 BOOT TEE lt BOOT TEE DRAIN COVER TRAP LOOP COMBUSTIBLE BOILER NSATE TUBING VENT FLOORING DRAIN 1 FIGURE 11 HORIZONTAL THROUGH THE WALL
54. S NK Xr 000009 000 098 000066 000 020 0000511 000 Occ 000 002 000 00 L 000 029 000 089 000 006 000 002 c 000 0S 000 096 tu n1g AAAS AAA ED 000 097 000009 000 0SS 000029 000 0S9 000069 000092 000018 000006 000066 0000811 000 00000 2 14 718 Oe 000 097 000 067 000 085 000 08S 000099 0000 2 000 0S6 000 007 002 ost __ 1 89 gz groe ookl er Q9 9219 14 S N LE 000 Jo enjeA sec 09 0 uo O AA U amp 0 Jo eunsseJg e edid pue 5591 Jo ISd 8 0 O M Ul PL JO seunssaJg SEH 10 MJ pue u edig Jo Ayloedey BUIUJON Ses jenjeN seoueijddy ses 104 ezis adig 9 318VL 29 FIGURE 17 CONNECTION DIAGRAM OUTSIDE CABINET EXTERNAL Y 1 TANK TEMPERATURE PROBE POWER EXTERNAL THERMOSTAT POWER EXTERNAL THERMOSTAT RETURN 20 or J21 SIGNAL Hm a POWERED ACCESSORIES OPTIONAL IGNITER F2 POWERED ACCESSORIES POWER SWITCH RETURN OPTIONAL CIRCUIT POWERED VENT GND OPTIONAL 5 AMP LOW WATER CUTOFF POWER OPTIONAL J4 LOW WATER CUTOFF SWITCH RETURN OPTIONAL LOW WATER CUTOFF GND OPTIONAL ALARM POWER OPTIONAL 17 ALARM GND OPTIONAL o OO m h N GAS SWITCH POWER o a b MODULATIN
55. The status of all dipswitches can be observed on the system status screen on the UIM TABLE 9 MCB FCB Dipswitches Dipswitch Function Switch Position Switch 2 Trials for ignition Switch 3 IRI Gas Valve Not Available Switch 5 Powered Venter Switch 6 Low Water Cut Off LWCO No Switch 7 Low Gas Pressure Switch 8 Modulation NOTE If the unit powers up with the number of stages selected by dip switches exceeding the number of FCBs the MCB will detect this condition and go into a hard lockout After changing the dipswitches the power must be cycled off and back on to accept any changes 2 3 4 10 Example of Dipswitch configuration VB model ignition trial not used tank remote probe no power vent No LWCO no low gas pressure modulation not used not used MCB Three position Dipswitch This dipswitch is similar to the MCB dipswitches described above 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 and Hi Gas options are the required selection within the MCB see Figure 17 TABLE 10 Dipswitch Function Switch 1 Spare LL Switch 2 Hi Gas pressure switch Switch 3 Number of Blower Speeds Example of Dipswitch configuration No High Gas 1 blower speed 35 LIGHTING amp OPERATION INSTRUCTIONS FOR MODELS VB VW 500 750 1000 FOR
56. VER INLET PROBE LOW GAS amp PWR VENT OPTIONAL OUTLET PROBE HIGH GAS amp LWCO OPTIONAL TANK PROBE FIGURE 18 SCHEMATIC DIAGRAM 32 OPERATION IMPORTANT Only qualified personnel shall perform the initial firing of the boiler At this time the user should not hesitate to ask the service agent any questions regarding the operation and maintenance of the unit If you still have questions please contact the factory or your local A O Smith representative Lighting and Operating instructions are included with this manual By using these instructions the user may be able to make minor operational adjustments and save unnecessary service calls However the user should not attempt repairs but should contact a service technician or gas supplier GENERAL Never operate the boiler without first making sure the boiler and system are filled with water in addition For hot water supply installations Make sure a temperature and pressure relief valve is installed at the boiler and if used the storage tank Also check for leaks For heating boiler installations Make sure that the boiler and system have been purged of air and checked for leaks Also be sure to check the gas piping for leaks before beginning the initial firing of the boiler FILLING AND PURGING OF HEATING BOILER INSTALLATION 1 Fast fill system through bypass until pressure approaches desired system pressure Close bypass valve and permit
57. YOUR SAFETY READ BEFORE OPERATING FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE PER SONAL INJURY OR LOSS OF LIFE WARNING IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY A 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 APPLIANCE AREA FOR GAS BE SURE TO SMELL NEXT TO THE FLOOR BECAUSE SOME GAS 15 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 A NEIGHBOR S PHONE FOLLOW THE GAS SUPPLIER S INSTRUCTIONS IF YOU CAN NOT REACH YOUR GAS SUPPLIER CALL THE FIRE DEPARTMENT GAS FLOW STOP READ THE SAFETY INFORMATION ABOVE ON THIS LABEL SET SYSTEM TEMPERATURE CONTROLLER TO LOWEST SETTING TURN OFF ELECTRIC POWER TO THE BOILER CLOSE MAIN VALVE TURN MAIN MANUAL GAS VALVE TO OFF OR CLOSED POSITION THE VALVE IS OFF WHEN THE HANDLE IS PERPENDICULAR TO THE GAS FLOW DIRECTION WAIT FIVE 5 MINUTES TO CLEAR OUT ANY GAS THEN SMELL FOR GAS _ INCLUDING NEAR THE FLOOR IF YOU SMELL GAS io FOLLOW B IN THE SAFETY INFORMATION ABOVE ON THIS LABEL IF YOU DO NOT SMELL GAS GO TO THE NEXT STEP FLAMMABLE A THIS APPLIANCE DOES NOT HAVE A PILOT IT 15 C USE ONLY YOUR HAND TO TURN THE MAIN MANUAL GAS VALVE NEVER USE TOOLS IF THE KN
58. a N E 20 AMP INTERNAL WIRING SHOWN PUMP FOR CLARITY gt 24VAC HOT 120VAC 1 e 2 24VAC RETURN e 24VAC RETURN DS1 GREEN LED 3 LINE POLARITY IS J2 CORRECT IF LIT XFMR 120VAC FCB3 120VAC CCB FCB1 120VAC 120VAC HOT F5 F7 EARTH GROUND BK VFD E 2 Variable Fre OO 7 7 Drive FCB4 FCB2 120VAC 120VAC THIS UNIT MAY HAVE ALL SOME OR NONE OF THE ABOVE OPTIONS POWER DISTRIBUTION BOARD PDB rece ce VB VW Variable Fire J20 or J21 MODULE m Wiring Diagram F2 CIRCUIT 5 AMP BLOWER PROVER POWER BK W 1 BLOWER PROVER RETURN HIGH BLOWER PROVER SW J17 HIGH GAS PRESSURE SWITCH POWER OPTIONAL BK W 3 HIGH GAS SW HIGH GAS PRESSURE SWITCH RETURN OPTIONAL R G 4 OPTIONAL BLOCKED INLET POWER BK W 5 BLOCKED INLET RETURN RIG LOW GAS sw VIODULATING i SPLICES IGNITER HOT NTROL BOARD N MCB me VALVE x E IGNITER RTN w on N R FLAME SENSOR 1 FLAME SENSOR SIGNAL R Cp x EXAMPLE ON OFF FLAME SENSOR 2 MODULATION KEY a D 5 m em VARIABLE FREQ DRIVE lt 9 4 sin o BLOWER J1 N 3 12 3 N C MCB DIP SWITCH Sw2 FUNCTIONS 5 SEE NOTES G Y 120 WIRING 5 LOW VOLTAGE WIRING FIELD INSTALLED COMMUNICATION CABLESSEE NOTES 120 WIRING 5 LOW VOLTAGE WIRING FIELD INSTALLED COMMUNICATION CA
59. according to the chosen options 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 TABLE 13 MCB FCB Dipswitches Dipswitch Function Switch Position Hot Water Boilers Hydronic Heating Boiler Switch 1 Selection of the type of boiler application Switch 2 Trials for ignition Switch 3 IRI Gas Valve Not Available Switch 4 Controlling Probe Switch 5 Powered Venter Switch 6 Low Water Cut Off LWCO Switch 7 Low Gas Pressure Switch 8 Modulation Off VB Tank Remote NOTE If the unit powers up with the number of stages selected by dip switches exceeding the number of FCBs the MCB will detect this condition and go into a hard lockout After changing the dipswitches the power must be cycled off and back on to accept any changes Example of Dipswitch configuration VB model 1ignition trial not used tank remote probe no power vent No LWCO no low gas pressure modulation not used not used 2 3 4 10 MCB Three position Dipswitch This dipswitch is similar to the MCB dipswitches described above 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 and Hi Gas options are the required selection within the MCB see Figure 17 TABLE 14 Dipswitch Functio
60. and Capacity Data in this manual A system bypass should be installed as shown in Figure 13 to prevent boiler circulation starvation when the system zones call for reduced flow This bypass may also be used with multiple boilers manifolded for reverse return flow This system bypass would be installed from boiler outlet to suction side of pump HOT WATER HEATING HYDRONIC EQUIPMENT The following is a brief description of the equipment required for the installations noted in this manual installations must comply with local code 1 WATER SUPPLY LINE These boilers can be used ONLY in a forced circulation hot water heating system Since most forced circulation systems will be of the closed type install the water supply line as shown on piping diagram see Figure 13 Fast filling of large pipe old radiator installations and pressure purging of series loop systems where high pressures are not available requires bypassing of the pressure reducing valve Generally pressure purging is not possible with a well pump system High point air venting is essential If the system is of the open type a pressure reducing valve will not be required as the water supply to the system will be controlled by a manually operated valve An overhead surge tank is required A minimum pressure of 15 psi 100kPa must be maintained on the boiler at all times to ensure avoidance of potential damage to the boiler which may not be covered by the warr
61. anty 2 EXPANSION TANK If the system is of the closed type install an expansion tank as shown in Figure 13 The sizing of the expansion tank for a closed system is very important and is directly 22 related to the total water volume of the system Refer to Systems and Equipment volume of the ASHRAE handbook An air separator as shown in the piping diagrams is recom mended especially for modern commercial hydronic systems VENT VALVES It is recommended that automatic loose key or screw driver type vent valves be installed at each convector or radiator SYSTEM HEADERS Split systems with individual supply and return lines from the boiler room should normally have this piping connected to supply and return manifold headers near the boiler To achieve good water distribution with maximum pressure drop for several circuits manifolds should be larger than system mains The circuits should be spaced on the heater at a minimum of 3 76mm center to center Install a balancing cock in each return line Manifold headers are recommended for split systems with or without zone valves and also those installations with zone circulators the system is to be split at remote points good practice requires special attention be given to main pipe sizing to allow balancing of water flow COOLING PIPING When the boiler is used in conjunction with a refrigeration system it must be installed so that the chilled medium is piped
62. as much distance FLOORING gt as possible between the combustion air intake and the exhaust vent terminal i TRAP LOOP VENT FIGURE 12 DIRECT VENT HORIZONTAL 10 MIN 3 0 M VERTCAL VENT TERMINAL 6 MIN 2 0 M gt AIR INTAKE L TERMINAL 2 um MM T FLASHING AX CAUTION Ur Direct venting into dead air spaces such as alleys atriums and inside corners can cause recirculation of flue gases Recirculation of flue gases will cause sooting premature failure of the heat exchanger and icing of the combustion air intake during severe cold weather To prevent the recirculation of flue gases maintain as much distance as possible between the combustion air intake and the exhaust vent terminal NOTES Ifthe exhaust vent terminal is within 10 3 0m of wall or parapet it must extend a minimum of 2 610mm above the wall or parapet Joints are not joined to show vent pipe orientation VERTICAL STRUCTURE LEVEL CURB 12 305 ANTICIPATED SNOW LEVEL TUA EEEBEEEN AL29 4C DOUBLE A WALL VENT 3 MIN 76 MM IN ROOF JACK CLEARANCE ALL AROUND FIRESTOP PSS 4 MIN 102 MM PVC COUPLING S IF NECESSARY 70 EQUIVALENT FEET 27 4 M OF VENTING MAX 90 ELBOW 10 3 0 M 45 ELBOW 5 1 5 M BOOT TEE 5 1 5 M I Lg LL S AL29 4C DOUBLE WALL VENT 4 INCH PVC PIPE ONLY THROUGH CEILI
63. ation on page 18 for complete venting installation instructions OUTDOOR AIR THROUGH TWO OPENINGS FIGURE 9A The confined space should be provided with two permanent openings one commencing within 12 inches 300 mm of the top and one commencing within 12 inches 300 mm of the bottom of the enclosure The openings should communicate directly with the outdoors See Figure 9A Each opening should have a minimum free area of 1 square inch per 4 000 Btu hr 550 mm per kW of the aggregate input rating of all appliances installed in the enclosure Each opening should not be less than 100 square inches 645 cm2 OUTDOOR AIR THROUGH ONE OPENING _ nm SSS FIGURE 9B Alternatively a single permanent opening commencing within 12 inches 300 mm of top of enclosure should be provided See Figure 9B The appliance should have clearances of at least 1 inch 25 mm from sides and back and 6 inches 150 mm from front The opening should directly communicate with outdoors or should communicate through a vertical or horizontal duct to outdoors or spaces that freely communicate with outdoors and should have a minimum free area of the following 1 1 square inch per 3000 Btu hr 700 per kW of the total input rating of all appliances located in the enclosure and 2 Not less than the sum of areas of all vent connectors in the space 12 OUTDOORAIR THROUGH TWO HORIZONTAL DUCTS FIGURE 9C The confined s
64. aved sidewalk or paved 7 feet 2 13 m t 7 feet 2 13 m driveway located on public property Clearance under veranda porch deck 12 inches 30 12 inches 30 cm t balcony Clearance to outside 2 feet 60 cm 2 feet 60 cm corner Clearance to inside 8 ft 2 44 m 8 ft 2 44 m corner 1 In accordance with the current CSA B149 1 Natural Gas and Propane Installation Code 2 In accordance with the current ANSI 2223 1 54 National Fuel Gas Code T Avent should not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings Permitted only if veranda porch deck or balcony is fully open on a minimum of two sides beneath the floor Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer s installation instructions 14 TERMINATION CLEARANCES SIDEWALL DIRECT VENT DIRECT VENT using outdoor air for combustion EXTERIOR CLEARANCES FOR SIDEWALL VENT TERMINATION IXED OPERABLE QLOSED V VENT TERMINAL AIR SUPPLY INLET AREA WHERE TERMINAL IS NOT PERMITTED NN Figure 9G Vent terminal clearances for Direct Vent installations Direct Vent configurations use outdoor air for combustion CANADIAN INSTALLATIONS I US INSTALLATIONS 4 CANADIAN INSTALLATIONS L US INSTALLATIONS a Clearance to each side of center line extended above meter regulator assembly 6
65. blue in color see Figure 21 NORMAL BURNER FLAME ABNORMAL BURNER FLAME FIGURE 21 BURNER FLAMES Visually check flame characteristics through the view port located on the top head of the boiler Figure 21 shows the normal flame condition These boilers are designed to give many years of efficient and satisfactory service when properly operated and maintained To assure continued good performance the following recommendations are made The area around the unit should be kept clean and free from lint and debris Sweeping the floor around the boiler should be done carefully This will reduce the dust and dirt which may enter the burner and heat exchanger causing improper combustion and sooting 45 MAIN BURNER Check main burner every three months for proper flame characteristics The main burner should display the following characteristics Provide complete combustion of gas Cause rapid ignition and carry over of flame across entire burner Give reasonably quiet operation during initial ignition operation and extinction Cause no excessive lifting of flame from burner ports see Figure 21 If the preceding burner characteristics are not evident check for accumulation of lint or other foreign material that restricts or blocks the air openings to the burner or boiler To check burners Shut off all gas and electricity to unit Allow unit to cool Remove main burners from unit Check that burner ports are free
66. ccur during ice build up or snowstorms The boiler must be isolated from the gas supply piping system by closing its main manual gas shut off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 psig Disconnect the boiler and its main manual gas shut off valve from the gas supply piping during any pressure testing of the gas supply system over 1 2 psig The gas supply line must be capped when not connected to the boiler It is important to guard against gas valve fouling from contaminants in the gas ways Such fouling may cause improper operation fire or explosion If copper supply lines are used they must be approved for gas service 24 When local codes require a main manual shut off valve outside the boiler jacket a suitable main manual shut off valve must be installed in a location complying with those codes Before attaching the gas line be sure that all gas pipe is clean on the inside To trap any dirt or foreign material in the gas supply line a drip leg sediment trap must be incorporated in the piping The drip leg must be readily accessible and not subject to freezing conditions Install in accordance with recommendations of serving gas supplier Refer to the current edition of the national fuel gas code ANSI 2223 1 B149 1 and current addenda Size of gas supply piping may be larger than heater connection on installations where a significan
67. cessive loads on the motor resulting in higher that normal operating temperatures and possible shortened service life BURNER MAINTENANCE Qualified servicers should follow this procedure when the boiler s burner needs cleaning 1 Turn off the electrical power to the boiler and close the main manual gas shutoff valve s Allow the boiler parts to cool before disassembly Loosen the flange and separate the gas train from the manifold assembly Separate the burner from the blower adapter by first removing the four 4 bolts and subsequently the blower gaskets The blower should be free to move at this point FOR DIRECT VENT UNITS It is necessary to loosen and slide the rubber coupling on the blower adaptor in order to move the blower Loosen the seven bolts on the blower adapter at the base and move the burner ground wire Green aside Lift the blower adapter and remove the manifold assembly up from the 6 studs located on the cover plate and remove the burner gasket Remove any loose foreign material such as dust or lint with a vacuum Check all ports for blockage Dislodge any foreign material causing blockage Remove any soot or carbon deposits with a rag making sure to remove any lint left on the burner by vacuuming again Reverse the steps to reassemble the unit Restore electrical power and gas supply to the boiler Put the boiler back in operation by following the Lighting and Operating instruction
68. dicates a watchdog reset occurred None 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 FCB did not receive command from MCB Continuous SOFT Caused when communications between the MCB 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 Water is not flowing Continuous SOFT Caused by the flow switch being open when it should be closed Check water lines pump flow switch contacts wiring Blower pressure is too low it they should have been closed Continuous SOFT Check blower switch contact wiring and for air leaks Flue is Blocked Continuous SOFT Caused by the blocked flue switch contacts being open when they should have been closed Check for flue blockage switch contacts wiring Air Inlet is blocked Check inlet terminal venturi screen and burner tube for debris If inlet is clear check blocked inlet flue switch for continuity Inspect hose to switch to ensure it is connected and not cracked or spilt Outlet temp exceeded high limit setpoint Continuous Auto Reset 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 Outl
69. e However if additional protection is desired install against the wall a non corrosive metal sheet under the TWT Due to the normal formation of water vapor in the combus tion process horizontal terminations must not be located over areas of pedestrian or vehicular traffic i e public walkways or over areas where condensate could create a nuisance or hazard This is especially true in colder climates where ice buildup is likely to occur A O Smith Corporation will not be held liable for any personal injury or property damage due to any dislodging of ice We 10 MIN 3 0 M VERTICAL STRUCTURE 1 0 M TO 2 0 M AL 29 4C DOUBLE WALL VENT IN ROOF JACK VERTICAL VENT TERMINAL ROOF JACK ASSEMBLY NOTES If the exhaust vent terminal is within 10 3 0m of a wall or parapet it must extend a minimum of 2 610mm above the wall or parapet LEVEL CURB CEILING 3 MIN 76 MM CLEARANCE ALL AROUND Joints are not joined to show vent pipe ee A 44 6 INCH 4 MIN 102 MM bebe WAIT 70 EQUIVALENT CLEARANCE VENT THROUGH FEET 54 9 M MAX ALL AROUND CEILING 70 ELBOW 10 3 0 M 45 ELBOW 5 1 5 M __ BOOT TEE 5 1 5 M 1 INLET AND OUTLET OF THE BOILER SUPPORT AS NECESSARY _ SUPPORT VENT CONDENSATE TUBING BOILER VENT 3 BETWEEN BOILER AND BOOT TEE AT THI
70. e boiler must be followed tud to avoid choked combustion Z5 recirculation of flue gases Such conditions cause sooting or risks of fire and asphyxiation VENT SIZING INSTALLATION AND TERMINATION SHALL BE IN ACCORDANCE WITH THIS INSTALLATION MANUAL ALL ELECTRICAL POWER AND GAS MUST BE TURNED OFF PRIOR TO ANY INSTALLATION OF THE VENTING SYSTEM SPECIAL INSTALLATION CONSIDERATIONS This boiler is a category IV appliance that can be vented using room air for intake combustion air or direct vented so that all intake air for combustion comes from the outside through a sealed pipe When installing this boiler as direct vent special vent kits are required In cold climates any water vapor remaining in the flue gases will condense into a cloud of vapor atthe point where the vent system exits the building Special consideration is recommended before locating the venttermination near walkways windows and building entrances Direct venting into dead spaces such as alleys atriums and inside corners can cause recirculation of flue gases Recirculation of flue gases will cause sooting premature failure of the heat exchanger and icing of the combustion air intake during severe cold weather To prevent the recirculation of flue gases maintain as much distance as possible between the combustion air intake and the exhaust vent terminal Due to large volumes of flue gases multiple boiler applications also require additional distance between t
71. e relief valve is furnished with the boiler Never operate the boiler if it is not filled with water and a properly sized pressure relief valve is not installed The pressure rating of the relief valve should be equal to or less than the rated pressure capacity of any component in the system including the boiler Should the valve need to be replaced call the toll free phone number listed on the back of this manual for further technical assistance e Relief Valve must comply with ASME code e Properly sized Relief Valve must be installed e Can result in overheating and excessive tank pressure e Can cause serious injury or death A discharge pipe from the relief valve should terminate at an adequate floor drain Do not thread plug or cap the end of drain line CAUTION Pressure Relief Valve discharge pipe must terminate at adequate drain The Discharge Pipe Shall not be smaller in size than the outlet pipe size of the valve or have any reducing couplings or other restrictions Shall not be plugged or blocked Shall not be exposed to freezing temperatures Shall be of material listed for hot water distribution Shall be installed so as to allow complete drainage of both the relief valve and the discharge pipe Must terminate a maximum of six inches above a floor drain or external to the building In cold climates it is recommended that the discharge pipe be terminated at an adequate drain i
72. e vented using AL29 4C material Transition from the horizontal outlet to a vertical vent is achieved through the use of a boot tee and drain cover or other engineering approved arrangement A support bracket should be located at the transition point The drain connection is necessary for the removal of condensate which may form in the stack A rubber hose 3 8 ID and 10 feet long is provided for directing the condensate to a suitable drain 1 Attach the Boot Tee Drain Cover to the appropriate leg of the Boot Tee see Figure 10 2 Atrap loop must be formed into the drain tube simply by looping the tube to a minimum 3 inch 76mm diameter and secure the loop with a cable tie see Figure 10 Prior to final assembly the trap loop must be primed by pouring a small quantity of water into the drain hose Connect the Boot Tee and Drain Tee assembly or engineering approved equivalent to the boiler vent connector see Figure 10 5 Attach the hose to the drain fitting and run the hose to a sanitary sewer drain maintaining the proper trap loop and following all local state and federal codes and regulations for draining of acidic effluent condensate 3i 4 INLET amp OUTLET OF THE BOILER SUPPORT VENT AT THIS TRANSITION POINT L MAINTAIN MIN CLEARANCE TO COMBUSTIBLES OF 4 102 MM DOUBLE WALL AL 29 4C VENT 6 152 MM SINGLE WALL AL 29 4C VENT 4 BOOT TEE 4 BOOT TEE DRAIN COVER
73. ect key touched the new value is IMMEDIATELY saved to non volatile memory The factory default setting is 120 F 49 C 1 Press the MENU key 2 Scroll the gt with the DOWN key next to the USER SETTING SCREEN 3 Press the SELECT key 4 Scroll the gt with the DOWN key until it is pointing to OPERATING SETPOINT 5 Press the SELECT key 6 Use the UP or DOWN key to select the value you wish to enter 7 Press the SELECT key to accept and store the new value High Limit The outlet temperature probe contains 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 AUTO HIGH LIMIT SETPOINT ADJUSTMENT PROCEDURE OUTLET TEMPERATURE PROBE The High Limit setpoint has a range of 90 F 32 C to 210 F 99 C for a VW and a range of 90 32 C to 235 F 113 C for a VB Use the following procedure to change the automatically resettable High Limit Setpoint 1 Press the MENU key 2 Scroll the gt with the DOWN key next to USER SETTING SCREEN 3 Press the SELECT key 4 Scroll the gt with the DOWN key until it is poi
74. ed spaces in buildings infiltration may be adequate to provide air for combustion ventilation and dilution of flue gases However in buildings of unusually tight construction for example weather stripping heavily insulated caulked vapor barrier etc additional air must be provided using the methods described in the Confined Space section that follows CONFINED SPACE A Confined Space is one whose volume is less than 50 cubic feet per 1 000 Btu hr 4 8 cm per kW of the total input rating of all appliances installed in the space Openings must be installed to provide fresh air for combustion ventilation and dilution in confined spaces The required size for the openings is dependent on the method used to provide fresh air to the confined space and the total Btu hr input rating of all appliances installed in the space DIRECT VENT APPLIANCES Appliances installed in a Direct Vent configuration that derive all air for combustion from the outdoor atmosphere through sealed intake air piping are not factored in the total appliance input Btu hr calculations used to determine the size of openings providing fresh air into confined spaces EXHAUST FANS Where exhaust fans are installed additional air should be provided to replace the exhausted air When an exhaust fan is installed in the same space with a water heater sufficient openings to provide fresh air must be provided that accommodate the requirements for all appliances in the ro
75. ence for the materials and methods of piping necessary for installation is essential that all water piping be installed and connected as shown on the diagrams Check the diagrams to be used thoroughly before starting installation to avoid possible errors and to minimize time and material cost It is essential that all water piping be installed and connected as shown on the diagrams Check the diagrams to be used thoroughly before starting installation to avoid possible errors and to minimize the time and material cost HARD WATER CONDITIONS Where hard water conditions exist water softening or the threshold type of water treatment is recommended This will protect the dishwashers coffee urns water heaters water piping and other equipment When water softening or water treatment is not practical a comparatively easy method of periodic lime removal from the unit may be employed SHUTOFF VALVES SHOULD BE INSTALLED FOR SERVICING BOILER HOWEVER LOCAL CODES SHALL GOVERN THEIR USAGE THERMAL EXPANSION CLOSED SYSTEM As water is heated it expands thermal expansion In a closed system the volume of water will grow when it is heated As the volume of water grows there will be a corresponding increase in water pressure due to thermal expansion Thermal expansion can cause premature tank failure leakage This type of failure is not covered under the limited warranty Thermal expansion can also cause intermittent Temperature Pressure
76. er 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 time stamps that have occurred The last error to occur is displayed first If a new error occurs this screen is presented to display the error e 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 VW Models Oper Setpnt Operating Setpoint 145 F 63 C Hi Limit High Limit Setpoint 210 F 99 C Hi Limit Dif High Limit Differential 20 F 11 C VB Models Oper Setpnt Operating Setpoint 190 F 88 C Hi Limit High Limit Setpoint 230 110 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 none 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 On the User Settings screen items that appear next to a
77. erature less than 120 F 49 C above its dew point Category IV appliances are often termed High Efficiency appliances P COVER REAR PANEL REAR VIEW OF BOILER FIGURE 8 CHEMICAL VAPOR CORROSION Boiler corrosion and component failure can be caused by the heating and breakdown of airborne chemical vapors Spray can propellants cleaning solvents refrigerator and air conditioning refrigerants swimming pool chemicals calcium and sodium chloride water softener salt waxes and process chemicals are typical compounds which 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 Also air which is brought in contact with the boiler should not contain any of these chemicals If necessary uncontaminated air should be obtained from remote or outside sources Failure to observe this requirement will void the warranty INSTALLTION CLEARANCES This boiler MUST NOT be installed on carpeted floors This boiler is approved for installation on combustible flooring in an alcove with minimum clearances to combustibles of 4 102mm Rear 0 Omm Top and Sides 6 152mm Vent 2 51mm clearance is allowable from combustible construction for hot water pipes Sufficient area should be provided at the front and rear of the unit for proper servicing Service clearances of 24 610mm
78. es and vent Such deposits are flammable and may be ignited by static electricity Use a metal brush to minimize the danger of explosion Qualified service agent should follow this procedure when the boiler s intake and exhaust piping need cleaning 1 Turn off the electrical power and manual gas shut off e Allow boiler parts to cool before disassembly Remove the vent pipe e Check parts and chimney for obstructions and clean as necessary Remove burner from boiler and other metal parts as required to clean as necessary e Refer to parts list for disassembly aid Clean and reinstall the parts removed in steps 2 and 3 e Be sure the vent pipe has a minimum upward pitch of 1 4 per foot 2cm m of length and is sealed as necessary Restore electrical power and gas supply to boiler e Check for gas leaks and proper boiler and vent operation 47 HEAT EXCHANGER PREVENTATIVE MAINTENANCE In most water supply systems solids exist As the water is heated these tend to drop out depositing as scale or lime This scale must be removed before the heat exchanger tubes become blocked CAUTION Lime accumulation can reduce the life of the equipment reduce efficiency and waste fuel Boiler failure due to lime or scale buildup voids the warranty DELIMING The amount of calcium carbonate lime released from water is in direct proportion to water temperature and usage The higher the water temperature or water usage
79. et temp is too high Flashing HARD Caused when the MRHL 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 probe or disconnected wiring Note The MRHL can be checked by disconnecting the outlet probe from the MCB 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 Water level is too low Flashing HARD Caused by the Low Water Cut Out device not closing its feedback switch contacts when it should Check water line switch contacts wiring LWCO Gas pressure is too low Flashing HARD Caused by the Low Gas switch being open when it should be closed Check gas line switch contacts wiring Power vent not running Flashing HARD 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 MCB Check output to powered vent switch contacts wiring Gas pressure too high Flashing HARD Caused by the High Gas switch being open when it should be closed Check gas line switch contacts wiring Inlet probe shorted or open Flashing HARD 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
80. h installations above 7000 feet Use only gas shown on rating plate Please contact an AO Smith qualified service agent to obtain the proper Maintain required clearances to combustibles E setup and instructions before lighting Keep ignition sources away from faucets after extended Failure to implement the proper setup will result in improper and inefficient d operation of the appliance resulting in Leon production of increased levels of period of non use 9 quid carbon monoxide gas in excess of the Wang serving safe limits which could result in serious personal injury or death Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual AWARNING CAUTION For continued protection against vis es Improper installation and use may result in property damage Do not install boiler on Donotoperate boiler ifflood damaged carpeted floor nstallin location with drainage Fill boiler with water before operation Do not operate boiler if flood Bealertforthermal expansion damaged Refer to instruction manual for installation and service DIMENSION AND CAPACITY DATA Minimum clearances to combustibles 4 102mm rear e 0 top amp sides 6 152mm vent FIGURE 1 TABLE 1 GAS AND ELECTRICAL CHARACTERISTICS LL Manifold Pressure C a
81. 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 or a fault occurs The system returns to the Idle state if the call for heat is cancelled or satisfied and to the appropriate fault state if a fault occur Inter Purge State The gas valve and the igniter are turned off The blower is on After approximately 15 seconds 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 If it does have a blower then the blower is left on After approximately 25 seconds the system returns to the Idle state Error State The gas valve and the igniter are turned off The FCB micro tells the MCB micro which error has occurred The system waits in this state until the MCB sends a command to clear the error and the system returns to the idle state 41 Cold Purge State Cold purge occurs when the MCB micro commands the blower to go on before lighting to clear the unit of residual gases This state normally lasts approximately 32 seconds but on a special situation can last up to 5 minutes on the first call for heat after power up blower prover switch is open this state will take up to 5 minutes before declaring an error The MCB will wait the normal cold p
82. he intake and exhaust terminals VENTING SYSTEM USING AL 29 4C This boiler may be installed in four separate orientations depending on the requirements of the building and the appliance The installer must decide which method is most appropriate for each installation These orientations are 1 Vertical Termination vertical vent termination through un enclosed or enclosed areas with roof penetration see Figure 11 16 Through the Wall Termination TWT horizontal vent termination directly through an outside wall see Figure 11A Horizontal Direct Vent using TWT to exhaust flue products and PVC piping to bring combustion air to the boiler from the outside see Figures 12 and 12C Vertical Direct Vent using a vertical vent termination to exhaust flue products and PVC piping to bring combustion air to the boiler from outside see Figures 12A and 12B GENERAL EXHAUST VENT INSTALLATION PROCEDURE Prior to beginning the installation of the vent system determine and obtain all parts required for the installation IF THIS INSTALLATION IS ADIRECT VENT INSTALLATIONA DIRECT VENT IS REQUIRED REFER TO THE PARTS LIST FOR KIT NUMBER Proper operation of the boiler and venting system is dependent upon use of all specified parts and installation techniques both safety and proper performance of the system may suffer if instructions are not followed CONNECTING VENT TO BOILER Referring to Figure 10 combustion gases ar
83. in front rear top and sides are recommended In a utility room installation the door opening shall be wide enough to allow the boiler to enter or to permit the replacement of another appliance such as a boiler LEVELING Each unit should be checked after installation to be certain that it is level If the unit is not level obtain and insert shims under the feet at the frame base to correct this condition AIR REQUIREMENTS AWARNING sp od gt e Install appliance in accordance with the Instruction Manual and NFPA 54 or CAN CSA B149 1 e To avoid injury combustion and ventilation air must be taken from outdoors e Do not place chemical vapor emitting products near water heater Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual 14 UNCONFINED SPACE In buildings of conventional frame brick or stone construction unconfined spaces may provide adequate air for combustion If the unconfined space is within a building of tight construction buildings using the following construction weather stripping heavy insulation caulking vapor barrier etc air for combustion ventilation and draft hood dilution must be obtained from outdoors or spaces freely communicating with the outdoors The installation instructions for confined spaces in tightly constructed buildings must be followed to ensure adequate air supply UNUSUALLY TIGHT CONSTRUCTION In unconfin
84. in parallel with the boiler Appropriate flow control valves manual or motorized must be provided to prevent the chilled medium from entering the boiler Water temperature in the heating system must be reduced to less than 100 F 38 C before cooling system is started or damage to the chiller unit may occur If the boiler is connected to chilled water piping or its heating coils are exposed to refrigerated air the boiler piping system must be equipped with flow valves or other automatic means to prevent gravity circulation through the boiler during the cooling cycle Primary secondary pumping of both the chiller s and the boiler s is an excellent winter summer change over method because cooling flow rates are so much more than heating flow rates In this way each system heating or cooling is circulated independently CIRCULATING PUMP FOR HOT WATER HEATING BOILERS VB MODELS the circulating pump is NOT provided and must be field installed NOTE If a system pump is to be installed on a VB model the maximum rating of the pump motor must not exceed 1 hp 7 SYSTEM CONTROLLER Controlling of these systems is decided mainly by the type of building system controlling desired A single boiler installation might be controlled directly from space temperature thermostat s Multiple boiler installations are more effective when the boilers are sequenced in and out of operation by some form of main water temperature controller W
85. ion use and servicing of this boiler is extremely important to your safety and the safety of others Many safety related messages and instructions have been provided in this manual and on your boiler to warn you and others of a potential injury hazard Read and obey all safety messages and instructions throughout this manual It is very important that the meaning of each safety message is understood by you and others who install use or service this boiler This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death DANGER indicates an imminently A DANGER hazardous situation which if not avoided will result in injury or death WARNING indicates a potentially hazardous WARNING situation which if not avoided could result in injury or death CAUTION indicates a potentially hazardous CAUTION situation which if not avoided could result in minor or moderate injury CAUTION used without the safety alert symbol indicates a potentially hazardous CAUTION situation which if not avoided could result in property damage All safety messages will generally tell you about the type of hazard what can happen if you do not follow the safety message and how to avoid the risk of injury The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substance
86. ircuit conductors and connected to the equipment grounding terminal or lead on the boiler INLET WATER CONSIDERATIONS To minimize the amount of condensate a minimum inlet water temperature to the heat exchanger of 120 F 49 C shall be maintained This temperature can be acquired by returning 120 F 49 C water from the remote storage tank to the boiler or by installing a by pass loop between the boiler s inlet and outlet connections When installing a by pass loop a remote probe MUST be used see SYSTEM INSTALLATION Circulating water through the boiler and to the remote storage tank if applicable is accomplished by a pump on VW models only For hot water heating systems using the VB model the circulating pump is NOT provided on standard models optional and must be field installed CORRECT GAS MAKE SURE THE GAS ON WHICH THE BOILER WILL OPERATE IS THE SAME AS THAT SPECIFIED ON THE BOILER RATING PLATE DO NOT INSTALL THE BOILER IF EQUIPPED FOR A DIFFERENT TYPE OF GAS CON SULT YOUR SUPPLIER PRECAUTIONS IF THE UNIT IS EXPOSED TO THE FOLLOWING DO NOT OPERATE UNTIL ALL CORRECTIVE STEPS HAVE BEEN MADE BY A QUALIFIED SERVICE AGENT 1 EXPOSURE TO FIRE 2 IF DAMAGED 3 FIRING WITHOUT WATER 4 SOOTING IF THE BOILER HAS BEEN EXPOSED TO FLOODING IT MUST BE REPLACED LIQUEFIED PETROLEUM GAS MODELS Boilers for propane or liquefied petroleum gas LPG are different from natural gas models A natural gas boiler
87. ith one or two boilers individual control settings at progressive temperature may be used For more than two boilers electronic sequencing controlling is recommended Individual controls or the separate stages of a step controller should start the boiler loop circulator and fire the boiler Some large installations may require the firing of more than one boiler per stage The system or primary circulator may or may not be controlled by the boiler sequencer When this pump is operated through the first switch of any type of step controller care should be taken to determine if a motor starter is needed due to insufficient switch capacity Multiple boiler installations are especially adapted to the use of outdoor reset for main water temperatures This feature is not mandatory but offers smooth efficient operation of a modern system Normal use of flow control valves is required to prevent cross circulation of zones as with any multiple pump system Large systems with multiple boilers should include main water temperature controls with or without outdoor reset to sequence the boiler on and off in relation to the load on the system 24VAC System Controller Optional VB models require a field supplied 24VAC operating control to be installed in the system such as loop thermostat indoor outdoor reset control sequencing panel or energy management system The connection for such devices is located in the junction box at the rear of
88. l also cause a jump to the error state Description of FCB control states Idle State When any error is declared during idle state The system will remain in this state until the MCB request a heating cycle or a cold purge Pre Purge State The blower is turned on After 10 to 34 seconds 34 seconds for cold purging the system switches to the Heat Igniter State Heat Igniter State The sequence of operation is as follows The igniter relay is energized and the heat up period begins After 18 20 seconds if the igniter has reached a minimum of 2 8 amps the gas valve safety circuit is then activated If in this amount of time the igniter fails to reach a minimum amp draw of 2 8 amps the unit will re cycle up to 3 times before locking out on igniter hardware failure If the igniter does reach the minimum required amp draw of 2 8 amps the gas valve circuit is energized and the system advances to Flame Check status 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 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
89. ling probe the unit will be controlled by the inlet probe and will not use the desired tank temperature as its base Refer to Connection Diagram Figure 17 in order to connect the remote probe to the boiler see Tables 9 10 13 and 14 for Dipswitch positions GAS CONNECTIONS A CAUTION The gas type must match the gas type on the rating plate Gas supply pressure must match pressure indicated on the rating plate Isolate boiler from gas supply piping system Disconnect boiler and main manual gas shutoff valve from gas supply during pressure testing of gas supply system Make sure the gas on which the boiler is to operate is the same as that specified on the rating plate Do not install the boiler if equipped for a different type of gas Consult your gas supplier This boiler is not intended to operate at gas supply pressure other than shown on the rating plate A lock up or positive shut off type regulator must be installed in the gas supply line Exposure to higher gas supply pressure may cause damage to gas valves which can result in fire or explosion If overpressure has occurred such as through improper testing of gas lines or emergency malfunction of the supply system the gas valves must be checked for safe operation Make sure that the outside vents on the supply regulators and the safety vent valves are protected against blockage These are parts of the gas supply system not the boiler Vent blockage may o
90. mentally disabled are at highest riskfor scald injury Feel water before bathing or showering Temperature limiting valves are available Read instruction manual for safe temperature setting HOT WATER CAN SCALD Boilers are intended to produce hot water Water heated to a temperature which will satisfy space heating clothes washing dish washing and other sanitizing needs can scald and permanently injure you upon contact Some people are more likely to be permanently injured by hot water than oth ers These include the elderly children the infirm or physically mentally disabled If anyone using hot water in your home fits into one of theses groups or if there is a local code or state law requiring a specific temperature water at the hot water tap then you must take special precautions In addition to using the lowest possible temperature setting that satisfies your hot water needs a means such as a mixing valve should be used at the hot water taps used by these people or at the hot water supply tank Mixing valves are available at plumbing supply or hardware stores Fol low the manufacturer s instructions for installation of the valves Before changing the thermostat setting on the hot water system controller see Table 8 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
91. n Switch 1 Spare LLL Switch 2 Hi Gas pressure switch Switch 3 Number of Blower Speeds Example of Dipswitch configuration No High Gas 1 blower speed OPERATING SEQUENCE 6 After a few seconds the blower is turned on for 30 second pre purge period of combustion chamber 1 The EMC modulation controller has four modes of operation Initialization Standby Running Modulation and Service The 7 The igniter is turned on internal MCB micros control these modes through a sequence g After the igniter has reached a minimum of 2 8 amps the gas of steps or States which are further described in the UIM valve is energized to allow gas flow to burner Operating Procedures section 9 After an additional one second the system checks the status of 2 When poweris applied to the system it enters the initialization the flame through the flame sensor If the flame is not verified mode and the following automatic functions are performed within 4 seconds the gas valve is immediately shut off followed Smith opening screen is displayed by 15 second inter purge period then the system returns to step 7 if the Trial for Ignition dipswitch is set for three 3 tries The system goes through a calibration indicated by the If the dipswitch is set for one 1 trial the system will declare green running LED blinking and then staying on next the an error and boiler will require resetting the control red service L
92. n death 8 a ps T o OM Vat T a ug aT x a Tar FAM LEM aS ux 5 Be m 1 PL Bam QF Ppa mu u 3 wa say Ee ogg oc L I n tit x e ak hk a R adn ee s av B oan r Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual There must be sufficient load to operate the boiler at high fire to perform the following adjustments Start the boiler and observe proper operating parameters for the system Required Tools TORX T40 or 5mm hex wrench 3mm or 7 64in hex wrench Combustion analyzer The VF 500 750 and 1000 boilers are equipped with a Honeywell combined gas air control and gas safety shut off control valves The valve functions in parallel with the variable speed combustion blower to supply the correct gas air ratio for optimum performance and efficiency The combustion blower speed is controlled automatically and determines the amount of negative pressure experienced by the gas safety shut off control valves The gas air regulator adjusts gas flow to maintain the proper pressure at the outlet nozzle of the associated valve SETTING OF THE TEST MODE On UIM go to main menu scroll down to user settings and press select Scroll down to MOD mode press select Use the up and down keys to select options MIN MINIMUM FIRING RATE MAX MAXIMUM FIRING RATE MOD FOR AUTOMATIC MODULATION
93. n the switch because of any restriction to the exhaust venting If the BFS is activated check and clear any obstructions causing the restriction LOW GAS SWITCH This VF boiler is available with a low gas pressure switch which meets the CSD 1 code requirements see Figure 5 The Low Gas Pressure Switch LGPS is normally closed and remains closed unless the pressure falls below the preset pressure FIGURE 5 LOW GAS PRESSURE SWITCH WATER FLOW SWITCH The water flow switch is installed at the boiler outlet to prevent burner operation in the event of inadequate water flow through the boiler It is a normally open switch that will close its contacts when increasing water flow rate is detected The water flow switch is factory set The contacts will open when the flow rate drops below the factory setting causing the gas valve to close which will turn off the gas to the burner see Figure 6 Under no circumstances shall the flow switch be tampered with or bypassed Doing so may cause damage to the heat exchanger not covered under the warranty SAFETY FLOW SWITCH FIGURE 6 WATER FLOW SWITCH FLAME SENSOR Each Boiler is equipped with two flame senors coupled together to detect the presence of the burner flames at high and low fire conditions These flame sensors work together as one to sense the flame If no flame is sensed the gas valve s will close automatically If no flame is sensed on three ignition trials the boiler will
94. ne use a pipe larger than specified to compensate for increased pressure drop TABLE 5 SINGLE UNIT INSTALLATION SUGGESTED GAS PIPE SIZING MAXIMUM EQUIVALENT PIPE LENGTH IN FEET w 0 3 in w c drop Nom Pipe k L L FM BTU input Nat Prop Nat Prop Nat Prop Nat Prop 00000 10 26 40 so 200 200 750 000 10 10 40 40 90 125 lt 1 000 000 10 20 20 50 70 175 500 000 10 40 60 150 150 200 lt 750 000 10 30 70 70 150 200 1 000 000 10 10 40 30 90 125 lt SNIdid AHVONOO3S TVOIdAL 34914 78 318V1 33S SSYNLXIA OL aariddfns YILYM LOH 3103 3ATVA Q 1VOS ILNV NV AAY 1Nd LNO uunjeJ pue Ajddns Buidid jo 129 juejeAinbe og uo peseq pezis s duind paljddns 4 H31SOO8 ALVNOAGV NIVLEO OL AHVSS3O3N eBesn Jeus sepoo 10 UMOUS 99IAJOS SaqsniviuddWal Ulejs s ay ui Aue Bunes eunsseJd jou Jeus Bunjes AJLA pue Z Jl SJXNLXIJ LV AYNLVYSdWNAL ASN 34vs Buidid 5 ONILLAS AYN 1V l3dIW3 L Q S3LON H395NVG W HOO 4 G3HSINI4 l 25 W31SAS WALSAS
95. nside the building Shall not have any valve or other obstruction between the relief valve and the drain Once the boiler is installed and filled with water and the system is pressurized manually test the operation of the pressure relief valve See the maintenance section of this manual for instructions Your local code authority may have other specific safety relief valve requirements not covered below If any pressure relief valve is replaced the replacement valve must comply with the current version of the ASME Boiler and Pressure Vessel Code Section IV HEATING BOILERS VW HOT WATER SUPPLY BOILERS are shipped with a 125 psi 860kPa pressure relief valve that must be installed in the water outlet as near to the boiler as possible This ASME rated valve has a discharge capacity that exceeds maximum boiler input rating and a pressure rating that does not exceed maximum working pressure shown on boiler rating plate In addition a CSA design certified and ASME rated temperature and pressure T amp P relief valve must be installed on each and every water storage tank in hot water supply system The T amp P relief valve must comply with applicable construction provisions of Standard for Relief Valves for Hot Water Supply Systems ANSI 221 22 or CSA 4 4 T amp P relief valve must be of automatic reset type and not embody a single use type fusible plug cartridge or linkage T amp P relief valve should have a temperature rating of 210
96. nting to HIGH LIMIT SETPOINT Press the SELECT KEY 6 Use the UP and DOWN key to select the value you wish to enter e 7 Press 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 HIGH LIMIT DIFFERENTIAL SETPOINT ADJUSTMENT PROCEDURE The High Limit Differential Setpoint has a range of 1 F to 50 F for all models Use the following procedure to change the High Limit Differential Setpoint 1 Press the MENU key 2 Scroll the gt with the down key next to USER SETTING SCREEN 3 Press the SELECT key Scroll the gt with the DOWN key until it is pointing to HIGH LIMIT DIFFERENTIAL SETPOINT Press the SELECT key Use the UP or DOWN key to select the value you wish to enter gt 0 Press the SELECT key to accept and store the new value Operating Differential Setpoints Each of the two stages has an independent Operating Differential setpoint 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 or continuous If the continuous value is selected the pump will remain on at all times and the post circulate state time
97. o support the connector DO NOT rivet or screw the straps to the conduit or otherwise puncture the conduit wall Instead wrap an extra loop of strap around the conduit to hold it in position or attach the strap to the center screw of the double wall AL 29 4C vent coupling if applicable VERTICAL INSTALLATION REQUIREMENTS 1 The vent system must terminate at least 3 feet 1 0m and no more than 6 feet 2 0m above the roof line and no closer than 10 feet 3 0m from any wall or vertical structure If the exhaust vent terminal is within 10 feet 3 0m of a wall or parapet it must extend a minimum of 2 feet 610mm above the wall or parapet see Figures 11 and 12 For direct vent installations the total distance of the vent system from the boiler vent connector to the vertical vent termination shall not exceed 70 equivalent feet 21 3m A maximum of three 90 elbows can be used Minimum vertical vent is 7 equivalent feet 2 1m for direct vent installations Standard minimum vertical vent length is 7 feet 2 1m plus Boot Tee See Figures 11 12A 12B and 12C for differences between standard and direct vent installations An AL 29 C Vent Vertical Vent Terminal must be used at the termination 17 4 Maintain a minimum of 6 feet 2 0m separation between the air intake and the exhaust terminals HORIZONTAL INSTALLTION REQUIREMENTS 1 The vent system must terminate with a AL 29 4C Vent Through the Wall Termination
98. obe as the Tank temperature on the default Temperatures screen QUAD THERMISTOR PROBE When connecting up to 4 boilers to a single storage tank one primary secondary hydronic heating system the optional Quad Thermistor Probe should be used The Quad Thermistor Probe is a remote temperature probe with four temperature sensors embedded in one device The Quad Thermistor Probe allows up to 4 boilers to sense system temperature from same point in the system Use of the Quad Thermistor Probe will allow each connected boiler to individually sense actual water temperature in the storage tank or hydronic heating loop The temperatures sensed from each of the four temperature sensor circuits in a Quad Thermistor Probe are shown as Tank temperature on each boiler s default Temperatures screen NOTE See the Field Wiring Remote Temperature Probe Installation and the Primary System Control sections of this manual for operating and installation instructions LOW WATER CUTOFF OPTIONAL If boiler is installed above radiation level a Low Water Cutoff Device must be installed in boiler outlet at time of installation or order pre installed from the factory If low water detection is required by authorities having jurisdiction a low water cutoff switch should be installed in the boiler outlet water line The switch should receive periodic every six months inspection to assure proper operation PRESSURE RELIEF VALVE An ASME rated pressur
99. ols have been designed to give both dependable service and long life However malfunction can occur as with any piece of equipment is therefore recommended that all components be checked periodically by a qualified service agent for proper operation RELIEF VALVE The safety relief valve should be opened at least twice a year to check its working condition This will aid in assuring proper pressure relief protection Lift the lever at the top of the valve several times until the valve seats properly and operates freely A DANGER Burn hazard Hot water discharge Keep hands clear of drain valve discharge A WARNING Should overheating occur or the gas supply fail to shut off turn off the manual gas control valve to the appliance COMBUSTION AIR FILTER If the combustion air supply to the boiler contains dust dirt drywall dust etc a filter must be installed An air filter is not supplied with the boiler as shipped from the factory The installer must provide a filtering system in the air inlet to the boiler if dust dirt or construction dirt can be pulled into the boiler through the inlet air piping Periodically clean air filter per the manufacturer s instructions BLOWER COMPARTMENT The blower compartment should be cleaned annually to remove any dirt and lint that may have accumulated in the compartment 46 or on the blower and motor Buildups of dirt and lint on the blower and motor can create ex
100. om and the exhaust fan Undersized openings will cause air to be drawn into the room through the appliance vent system causing poor combustion Sooting serious damage to the appliance and the risk of fire or explosion may result It can also create a risk of asphyxiation LOUVERS AND GRILLES The free areas of the fresh air openings in the instructions that follow do not take in to account the presence of louvers grilles or screens in the openings The required size of openings for combustion ventilation and dilution air should be based on the net free area of each opening Where the free area through a design of louver or grille or screen is known it should be used in calculating the size of opening required to provide the free area specified Where the louver and grille design and free area are not known it should be assumed that wood louvers will have 2596 free area and metal louvers and grilles will have 75 free area Non motorized louvers and grilles should be fixed in the open position FRESH AIR OPENINGS FOR CONFINED SPACES The following instructions should be used to calculate the size number and placement of openings providing fresh air for combustion ventilation and dilution in confined spaces The illustrations shown in this section of the manual are a reference for the openings that provide fresh air into confined spaces only Do not refer to these illustrations for the purpose of vent installation See Venting Install
101. ontrol System Section bus FIGURE 2 HOT SURFACE IGNITER The Hot Surface Igniter is a device that ignites the main burner by high temperature gt 1800 F 982 C see Figure The igniter is made of recrystallized silicon carbide and when 120 VAC is applied to the igniter sufficient heat is generated to ignite the main burner Although improvements have been made to strengthen the igniter it is still fragile and care must be taken in handling the igniter to prevent breakage i FIGURE 3 FIGURE 4 PRESSURE SWITCHES This control system has 3 pressure switches that are standard Blocked Inlet Pressure Switch BIS Blower Prover Switch BPS Blocked Flue Switch BFS The BPS onthis model is a normally open switch that closes on increased vacuum Once the blower moves enough airto create a vacuum across the Venturithe BPS is activated Ifthe blower fails or cannot move sufficient air a soft lockout will occur Inspect the blower for correct operation The Blocked Inlet Switch BIS will activate is the intake is blocked only during the heating cycle The BIS is a normally closed pressure switch that opens when the air intake is blocked If the BIS is activated check and clear the intake of any obstructions The blocked flue pressure switch BFS activated when the exhaust 8 flue of the unit is restricted or blocked The BFS is a normally closed switch that opens when positive pressure is placed o
102. osts may include but are not limited to a Labor charges for service removal repair 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 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 or provincial law are limited to one 1 year duration for the boiler or any of its parts Some states and 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 this 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 practicable the owner should contact U S Customers Canadian Customers A O Smith Corporation A O Smith Enterprises Ltd 500Tennessee Waltz Parkway P O Box 310 768 Erie Street Ashland City TN Stratford Ontario N5A 6T3 Telephone 800 527 1953 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
103. pace should be provided with two permanent horizontal ducts one commencing within 12 inches 300 mm of the top and one commencing within 12 inches 300 mm of the bottom of the enclosure The horizontal ducts should communicate directly with the outdoors See Figure 9C Each duct opening should have a minimum free area of 1 square inch per 2 000 Btu hr 1100 mm per kW of the aggregate input rating of all appliances installed in the enclosure When ducts are used they should be of the same cross sectional area as the free area of the openings to which they connect The minimum dimension of rectangular air ducts should be not less than 3 inches OUTDOOR AIR THROUGH TWO VERTICAL DUCTS The illustrations shown in this section of the manual are a reference for the openings that provide fresh air into confined spaces only Do not refer to these illustrations for the purpose of vent installation See Venting Installation on page 19 for complete venting installation instructions ay at w a ae gt 1 FIGURE 9D The confined space should be provided with two permanent vertical ducts one commencing within 12 inches 300 mm of the top and one commencing within 12 inches 300 mm of the bottom of the enclosure The vertical ducts should communicate directly with the outdoors See Figure 9D Each duct opening should have a minimum free area of 1 square inch per 4 000 Btu hr 550 per kW of the aggregate input rating of all ap
104. pliances installed in the enclosure When ducts are used they should be of same cross sectional area as free area of openings to which they connect The minimum dimension of rectangular air ducts should be not less than 3 inches AIR FROM OTHER INDOOR SPACES 13 The confined space should be provided with two permanent openings one commencing within 12 inches 300 mm of the top and one commencing within 12 inches 300 mm of the bottom of the enclosure See Figure 9E Each opening should communicate directly with an additional room s of sufficient volume so that the combined volume of all spaces meets the criteria for an Unconfined Space Each opening should have a minimum free area of 1 square inch per 1 000 Btu hr 1100 mm per kW of the aggregate input rating of all appliances installed in the enclosure Each opening should not be less than 100 square inches 645 cm TERMINATION CLEARANCES SIDEWALL POWER VENT POWER VENT using room air for combustion EXTERIOR CLEARANCES FOR SIDEWALL VENT TERMINATION IXED OPERABLE CLOSED V VENT TERMINAL AIR SUPPLY INLET AREA WHERE TERMINAL IS NOT PERMITTED NN Figure 9F Vent terminal clearances for Power Vent installations Power Vent configurations use room air for combustion CANADIAN INSTALLATIONS US INSTALLATIONS CANADIAN INSTALLATIONS US INSTALLATIONS 5 eee feet 1 em within a height 15teet Cd ini above meter regulator
105. ponsibility for the inspection and code approval of gas piping up to and including the Natural Gas meter or Propane storage tank of a building Many gas suppliers also offer service and inspection of appliances within the building GENERAL SAFETY DANGER Read and understand this manual and all Warnings and Cautions within before installing and using this appliance Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance Place these instructions adiacent to boiler and notify owner to keep for future reference G Untempered hotwater can cause Flammable Vapors severe burns instantly resulting Insevereinjury or death Children elderly and the a A physically or mentally disabled a WARNING are at highest risk for scald injury m Explosion Hazard Feel water before bathing or showering Temperature limiting Z Overheated water can cause valves are available m water tank explosion Read instruction manual for safe temperature setting Properly sized temperature and pressure relief valve must be installed A DANGER Fire or Explosion Hazard Do not store or use gasoline or other flammable vapors and liquids in the vicinity ofthis or any other appliance Avoid all ignition sources if you smell LP gas Special consideration must taken Do not expose boiler control to excessive gas pressure wit
106. pressure to be established by the pressure reducing valve 2 Vent all high points in system to purge system of air Provisions should be made to permit manual venting of radiators or convectors FILLING HOT WATER SUPPLY BOILER INSTALLATION 1 Close the system s drain valve by turning handle clockwise 2 Open a nearby hot water faucet to permit the air to escape 3 Fully open the cold water inlet pipe valve allowing the boiler and piping to be filled Close the hot water faucet as water starts to flow The boiler is ready to be operated 4 5 PURGING GAS LINE Gas line purging is required with new piping or systems in which air has entered 33 CAUTION Purging should be performed by persons experienced in this type of gas service to avoid risk of fire or explosion Purge discharge must not enter confined areas or spaces where ignition can occur The area must be well ventilated and all sources of ignition must be deactivated or removed Before placing the boiler in operation check for gas leakage Use a soap and water solution or other material acceptable for the purpose of locating gas leaks Do not use matches candles flame other sources of ignition for this purpose A WARNING The manual gas valve must be in the off position for at least five minutes This waiting period is an important safety step to permit gas in the combustion chamber to clear If you detect gas odor at the end of the five minu
107. rain It should be located in an area where leakage from the boiler or connections will not result in damage to the adjacent area or to lower floors of the structure A WARNING Flammable items pressurized containers any other potential fire hazardous articles must never be placed on adjacent to ihe boiler Open containers or flammabte material should not be stored or used in the same room with the boiler DANGER There is a risk of fire or explosion in areas where gasoline other flam mable liquids or engine driven equipment and vehicles are stored operated or repaired when a fuel burning appliance such as a boiler is operated Flammable vapors are heavy and 1 travel along the floor They may be ignited by sparks causing fire or explosion If the boiler is installed above radiation level a Low Water Cutoff Device must be installed in the boiler outlet at the time of installation PANELS AND COVERS All panels and covers e g control and junction box covers front side and rear panels of boiler see Figure 8 MUST be in place after service and or before operation of the boiler This will ensure that all gas ignition components will be protected from water The VF is low pressure boiler Category IV to be used as either hot water supply domestic commercial water heating or hot water heating hydronic application Category IV boilers operate with a positive vent pressure and with a vent gas temp
108. red LED indicates that a fault 43 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 UIM is in the initialization mode and the touch switches are being calibrated The VF boiler has a display on the UIM which is a scaled display indicating the current firing rate of the boiler 25 to 100 Fault Messages and Troubleshooting Guide The EMC 5000 modulation system does excessive self diagnostics and displays detected faults on the UIM display in an easy to read manner 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 the 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 it the fault clears itself the system resets itself The following table shows the fault messages and some possible troubleshooting hints FAULT DISPLAYED Display Fail Comm Fail Stg Low AC Voltage
109. s in this manual Check for gas leaks and proper boiler and vent operation CONDENSATE REMOVAL SYSTEM Due to the highly efficient operation of this unit condensate is formed during operation and must be removed by the conden sate drain systems Inspect the condensate drains and tubes at least once a month and insure they will allow the free flow of condensate at all times The system must be inspected more frequently in cold weather if the drain system is located in an area such as along the floor where freezing temperatures are likely to occur The condensate drain system must be protected against freezing Contact a qualified service agent to inspect and correct the condition if freezing of the condensate lines is a problem The unit is equipped with a blocked flue switch which will shut the unit off if condensate is unable to drain and backs up in the unit A blocked flue error will appear when sufficient condensate accumulates for this condition The transparent drain lines and condensate drain on the bottom of the vent collector should be visually inspected at one month intervals for blockage particularly in the areas of the loops in the lines which trap a small amount of condensate and the exit point of the vent collector drain Condensate in portions of the line other than the loop area indicates a blockage in the drain line Flush the lines with air water and clear replace the blocked portions of the line as necessary
110. s known to the State of California to cause cancer birth defects or other reproductive harm and requires businesses to warn of potential exposure to such substances This product contains a chemical known to the State of California to cause cancer birth defects or other reproductive harm This appliance can cause low level exposure to some of the substances listed in the Act IMPORTANT DEFINITIONS e Qualified Installer A qualified installer must have ability equivalent to a licensed tradesman in the fields of plumbing air supply venting and gas supply including a thorough understanding of the requirements of the National Fuel Gas Code as it relates to the installation of gas fired boilers The qualified installer must have a thorough understanding of this instruction manual Service Agency A service agency also must have ability equivalent to a licensed tradesman in the fields of plumbing air supply venting and gas supply including a thorough understanding of the requirements of the National Fuel Gas Code as it relates to the installation of gas fired boilers The service agency must also have a thorough understanding of this instruction manual and be able to perform repairs strictly in accordance with the service guidelines provided by the manufacturer e Gas Supplier The Natural Gas or Propane Utility or service who supplies gas for utilization by the gas burning appliances within this application The gas supplier typically has res
111. s stipulated in the limited warranty in this installation manual If any of the original wire as supplied with the appliance must be replaced it must be replaced with type 105 C wire or its equivalent CAUTION Using a multi meter check the following voltages at the circuit breaker panel prior to connecting any equipment Make sure proper polarity is followed and house ground is proven To eliminate the possibility of electrical interference to the boiler controls this figure must be confirmed H 120 volt hot N 120 volt neutral Confirm RMS voltage between Hot to gnd 108 VAC Minimum 132 VAC MAX Hot to neutral 108 VAC Minimum 132 VAC MAX Neutrally grd 1 VAC Maximum Verify that circuit breaker is properly sized by referring to heater rating plate A dedicated circuit breaker should be provided Figure 16 28 There are five 5 electrical connections that must be made for the unit to operate correctly 1 BLACK No Stripe 120V HOT 2 WHITE 120V NEUTRAL 3 GREEN GROUND 4 2 TANK PROBE OR 2 ENABLE DISABLE Enable disable can also be used with a 24 volt thermostat Do not use tank probe when using thermostat These connections shall be made at the rear of the unit where a junction box is provided AN ELECTRICAL GROUND IS REQUIRED TO REDUCE THE RISK OF ELECTRIC SHOCK OR POSSIBLE ELECTROCUTION A GROUND SCREW IS PROVIDED IN THIS JUNCTION BOX NOTE Tank probes are not provided on VB models
112. t gate ball valve until the desired outlet water temperature 120 F 49 C minimum is reached Wait one minute Note the outlet and inlet temperature indicator readings a If the inlet water temperature is less than 120 F 49 C open in small increments the bypass balancing valve until the minimum 120 F 49 C inlet water temperature or 20 F 11 C differential whichever has the higher inlet temperature is attained If the inlet water temperature is greater than 120 F 49 C and the 20 F 11 C differential is not present close the bypass valve until the 20 F 11 C differential is attained NOTE It may be necessary to make further adjustments on the outlet and bypass valves until the desired inlet and outlet water temperatures are reached MANIFOLD PRESSURE CONNECTIONS Take the manifold pressure refer to Table 1 by removing the pipe plug and inserting a suitable 1 8 NPT hose barb for connection to the manometer pressure gauge Upon completion of measurements and adjustments remove the hose barb and replace the pipe plug Check for gas leaks and insure all connections are gas tight see Figure 19 Ten Position Dipswitch Dipswitch configurations are READ ONLY ON POWER UP These switches are only to be set at the factory or by authorized trained personnel Once set the boiler will operate according to the chosen options If a switch is changed power must be cycled before the change will take effect
113. t run of piping is required To prevent damage care must be taken not to apply too much torque when attaching gas supply pipe to boiler gas inlet Fittings and unions in the gas line must be of the metal to metal type Apply joint compounds pipe dope sparingly and only to the male threads of pipe joints Do not apply compound to the first two threads Use compounds resistant to the action of liquefied petroleum gases GAS SUPPLY LINE SIZING The gas piping installation must be capable of supplying the maximum probable gas demand without excessive pressure loss Depending on local practices the ALLOWABLE PRESSURE LOSS between the gas meter or service regulator and each appliance is generally 0 3 or 0 5 inches of water column 0 075 or 0 124kPa For single boiler installation refer to Table 5 for appropriate pipe length for the appliance maximum rate For multiple boilers refer to Table 6 for natural gas and Table 7 for propane Maximum pressure drop is 0 5 for these charts Reference tables are from ANSI Z223 1 National Fuel Gas Code or CAN CSA B149 1 00 and current addenda Natural gas is 1000 BTU ft 0 6 specific gravity Propane gas is 2500 BTU ft 1 5 specific gravity lt pipe length longer than 200 feet consult applicable codes No additional allowance is necessary for an ordinary number of fittings Where it is necessary to use more than the average number of fittings i e elbows tees and valves in gas supply li
114. t temperature drops below the high limit trip point minus the high limit differential outlet water temperature drops to safe level The fault is logged 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 pump remains on for the selected post circulate time to cycle the hot water out of the boiler The FCB is 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 MCB is in the Heating mode the FCB 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 for heat is satisfied the thermostat input is opened or fault occurs When heat is satisfied the sequence continues to Post Purge and then back to Idle If three tries for ignition has been selected on the MCB 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 wil
115. te period do not proceed with lighting Gas odor even if it seems weak may indicate the presence of accumulated gas in the area with risk of fire or explosion See the front page of this manual for necessary steps INLET GAS PRESSURE The inlet gas pressure is measured by removing the 1 8 NPT Plug located on the main gas manifold which is upstream of the unit s gas valve and insert a 1 8 NPT hose barb fitting to be connected to a manometer or pressure gauge Once pressure has been checked and or adjusted replace the plug and check for leaks The maximum value specified in the table must not be exceeded The minimum values shown in Table 1 must be maintained under both load and no load conditions static and firing conditions The combination gas valves supplied with the boiler are for low pressure service If upstream pressure exceeds 14 0 W C an intermediate gas pressure regulator of the lockup type must be installed FIGURE 19 GAS TRAIN ASSEMBLY A CAUTION Should overheating occur or the gas supply fail to shut off turn off the gas supply at a location external to the boiler i e main manual gas shutoff valve Light the boiler in accordance with the instructions provided on the label affixed to the boilers front door on the inside WATER TEMPERATURE REGULATION DANGER Untempered hotwater can cause severe burns instantly resulting in severe injury or death Children elderly and the physically or
116. the coil of an externally connected contactor Blower MCB 120VAC required Variable speed blowers utilize the high blower output only Igniter MCB 120VAC required Provides power to operate the HSI igniters Gas Valve MCB 24VAC required Provides power to activate the gas valve The gas valve cannot be activated when the MRHL contacts are open Low Water Cut Off MCB 24VAC optional Directly connected to the 24VAC line to provide power to operate an external LWCO device MCB AND PDB INDICATOR LAMPS AND FUSES A green LED is mounted on the PDB to indicate when line voltage is applied the PDB also contains a yellow and red LED and a test run jumper that are used during installation to verify proper power connections A red LED on the MCB is used to indicate when the 24VAC input fuse has blown Yellow LEDs are located near the microcontrollers on the MCB These LEDs are heartbeat indicators and blink approximately twice per second to indicate that the microcontrollers are running MCB JUMPERS The MCB has two jumpers JP1 on the MCB is used to terminate the external communications line It is normally left off and installed when the external cable is very long IGNITERS The EMC modulation system operates with Silicon Carbide Igniters Dipswitch configurations are READ ONLY ON POWER UP These switches are only to be set at the factory or by authorized trained personnel Once set the boiler will operate
117. the more lime deposits are dropped out of the water This is the lime scale which forms in pipes boilers and on cooking utensils The usage of water softening equipment greatly reduces the hardness of water However this equipment does not always remove all of the hardness lime For this reason it is recommended that a regular schedule for deliming be maintained The time between cleaning will vary from two to six months depending upon water conditions and usage A change of approximately 5 F 3 C in the normal temperature rise through the boiler is usually an indication that scale should be removed For long life copper or brass is recommended for all valves pipe and fittings TUBE CLEANING PROCEDURE MECHANICAL REMOVAL OF DEPOSITS Establish a regular inspection schedule the frequency depends on the local water conditions and severity of service Do not let the tubes clog up solidly Clean out deposits over 1 16 1 6mm thickness To service heat exchanger tubes remove return header casting on the side opposite the water connections Use a U S standard 5 8 deep socket ratchet to remove the nuts exposing the tube ends Inspect to ensure tubes are free of scale and deposits If scaled remove deposits with a stiff wire brush or mechanical tube cleaner to bare metal Reinstall return header casting Flush system Note Removal of the heat exchanger is not required REPLACEMENT PARTS Replacement parts may be ordered through
118. uit Flashing HARD Caused by improper line power being applied to the igniter circuitry Check line connections Paying particular attention to the earth ground connection Also check that line voltage does not exceed 132 VAC RMS Hardware problems with igniter circuit Flashing HARD 44 TROUBLESHOOTING GAS VALVE Problem Non linear CO curve on adjusted boiler deviation more than 3 6 1 Possible blockage at the air inlet that prevents uniform constant air flow 2 The gas inlet pressure is too low at full load Problem Unstable CO level at minimum load The minimum load low fire is too low The pressure difference on the pressure regulator at minimum load must be at least 0 2 in wc 50 Pa If the pressure difference does not meet this requirement it may be necessary to adjust low fire setting see Setting Test Mode The pressure difference on the regulator can be measured between the venturi and the feedback tube It is necessary to unscrew the pressure tap on the venturi for this measurement and to close it afterwards With 17 of the reference load and a CO level of 8 7 it should be possible to reach this minimum pressure difference If the CO level is higher the minimum power also has to be proportionally higher than 1796 Problem No gas no burner start up Check whether both coils of the two shutoff valves are energized and whether both shutoff valves are opening you should hear a double click in the valve
119. urge time normally 32 seconds before checking for activation of all active blower prover If blower prover is active at this time the MCB 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 minute delay Any further requests for cold purge will last the normal cold purge time The FCB will go into fault mode if the blower 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 F 21 C to 190 F 88 C for a VW and of 70 F 21 C to 220 F 104 C for a VB for either a Remote or inlet probe depending on selection 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 Sel
120. warrantor DISCLAIMERS NO OTHER EXPRESS WARRANTY HAS BEEN OR WILL BE MADE ON BEHALF OF THE WARRANTOR 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 and 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 Zip Code Date Installed Model No Serial No Dealer s Name Phone No Dealer s Address FILL IN WARRANTY AND KEEP FOR FUTURE REFERENCE 51 Smith 500 Tennessee Waltz Parkway Ashland City TN 37015 Phone 800 433 2545 www hotwater com E Mail parts hotwater com
121. 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 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 earlier 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 kBtu rating of the boiler 0 to 5750kBtu in 10kBtu increments The software revision level of the MCB Current Error Screen Displays the last error that the system has detected plus a time stamp of when the error occurred The time stamp is based on the elapsed hours value at the time the error occurred is displayed in hours and minutes This error remain displayed as long as it is still valid 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 pow
122. will not function safely on LP gas and no attempt should be made to convert a boiler from natural gas to LP gas LP gas must be used with great caution It is highly explosive and heavier than air It collects first in the low areas making its odor difficult to detect at nose level If LP gas is present or even suspected do not attempt to find the cause yourself Leave the building leaving doors open to ventilate then call your gas supplier or service agent Keep area clear until a service call has been made At times you may not be able to smell an LP gas leak One cause is odor fade which is a loss of the chemical odorant that gives LP gas its distinctive smell Another cause can be your physical condition such as having a cold or diminishing sense of smell with age For these reasons the use of a propane gas detector is recommended IF YOU EXPERIENCE AN OUT OF GAS SITUATION DO NOT TRY TO RELIGHT APPLIANCES YOURSELF Call your local service agent Only trained LP professionals should conduct the required safety checks in accordance with industry standards HIGH ALTITUDE INSTALLATIONS A WARNING Special consideration must be taken with installations above 7000 feet Please contact an AO Smith qualified service agent to obtain the proper setup and instructions before lighting Failure to implement the proper setup will result in improper and inefficient operation of the appliance resulting in production of increased
123. y vented gas equipment provides a venting system design or venting system components with the equipment the instructions provided by the manufacturer for installation of the equipment and the venting system shall include 1 Detailed instructions for the installation of the venting system design or the venting system components and 2 Acomplete parts list for the venting system design or venting system MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases but identifies special venting systems the following requirements shall be satisfied by the manufacturer 1 The referenced special venting system instructions shall be included with the appliance or equipment installation instructions and 2 The special venting systems shall be Product Approved by the Board and the instructions for that system shall include a parts list and detailed installation instructions A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment all venting instructions all parts lists for venting instructions and or all venting design instructions shall remain with the appliance or equipment at the completion of the installation 19 INTERIOR 9 59 m WALL HANGER STRAPS THROUGH THE WALL TERMINAL MAINTAIN MINIMUM CLEARANC

A.O. Smith VB/VW- 1000 User's Manual

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