A.O. Smith 101 User Manual

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GAS-FIREDPOWER BURNER

COPPER BOILERS FOR HYDRONIC HEATING

 

AND HOT WATER SUPPLY

USER’S MANUAL

 

 

Installation

MODELS:

Operation

VB/VW-500,750 AND 1000

Maintenance

SERIES 100/101

Limited Warranty

 

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.

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS:

Do not try to light any appliance.

Do not touch any electrical switch; do not use any phone in your building.

Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

If you cannot reach your gas supplier, call the fire department.

Installation and service must be performed by a qualified installer, service agency or the gas supplier.

MC BEE, SC., RENTON, WA.,

STRATFORD-ONTARIO,VELDHOVEN-THENETHERLANDS,

NANJING, CHINA

www.hotwater.com / email: parts@hotwater.com

PRINTED 0207

212801-000

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SAFE INSTALLATION, USE AND SERVICE

Your safety and the safety of others is extremely important in the installation, use, and servicing of this boiler.

Many safety-relatedmessages and instructions have been provided in this manual and on your own 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.

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.

IMPORTANT DEFINITIONS

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.

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 responsibility 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.

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GENERAL SAFETY

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CONTENTS

 

SAFE INSTALLATION, USE, AND SERVICE .......................................................................................................................................

2

GENERAL SAFETY ................................................................................................................................................................................

 

3

TABLE OF CONTENTS .........................................................................................................................................................................

 

4

Installation Requirements for the Commonwealth of Mass ...................................................................................................................

5

Wiring Diagram ....................................................................................................................................................................................

 

6-7

Schematic Diagram ................................................................................................................................................................................

 

8

Lighting

and Operating Instructions.......................................................................................................................................................

9

Water Temperature Regulation ............................................................................................................................................................

 

10

Control

System ................................................................................................................................................................................

 

10-11

Operating Sequence .............................................................................................................................................................................

 

11

UIM Operating Procedures ..................................................................................................................................................................

 

12

Operating Setpoint Adjustment

Procedure ..........................................................................................................................................

14

TROUBLESHOOTING IGNITION SYSTEM .........................................................................................................................................

16

Troubleshooting Gas Valve..............................................................................................................................................................

 

17

PREVENTATIVE MAINTENANCE ........................................................................................................................................................

17

Main Burners ....................................................................................................................................................................................

 

17

Relief Valve ......................................................................................................................................................................................

 

18

Combustion Air Filter .......................................................................................................................................................................

 

18

Blower Compartment ........................................................................................................................................................................

 

18

Burner Maintenance .........................................................................................................................................................................

 

18

Condensate Removal System .........................................................................................................................................................

18

Venting Maintenance ........................................................................................................................................................................

 

19

Heat

Exchanger Preventive

Maintenance .......................................................................................................................................

19

Tube

Cleaning Procedure................................................................................................................................................................

 

19

REPLACEMENT PARTS ......................................................................................................................................................................

 

19

LIMITED WARRANTY ..........................................................................................................................................................................

 

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INTRODUCTION

 

This design complies with the current edition of the ANSI Z21.13 low-pressureboiler standard.

Compliance under this standard implies that when the boiler underwent test, the gas manifold and control assembly provided on the 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.

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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 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 backup 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-upmay 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 CARBON 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 thanone-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 horizontally 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.A complete 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.

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CONNECTION DIAGRAM

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VB/VW-500,750 & 1000 SCHEMATIC DIAGRAM

SCHEMATIC DIAGRAM

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LIGHTING & OPERATION INSTRUCTIONS FOR MODELS VB/VW 500, 750 AND 1000:

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WATER TEMPERATURE REGULATION

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.

The boiler should be located in an area that is inaccessible to the general public.

TABLE 1. Risk of Scalds.

Temperature

Time to Produce 2nd & 3rd

Setting

Degree Burns on Adult Skin

Over 170°F (77°C)

Nearly instantaneous

160°F (71°C)

About 1/2 second

150°F (66°C)

About 1-1/2seconds

140°F (60°C)

Less than 5 seconds

130°F (54°C)

About 30 seconds

120°F (49°C) or less

More than 5 minutes

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 others. 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 shall 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. Follow the manufacturer’s instructions for installation of the valves. Before changing the thermostat setting on the hot water system controller, see Table 1.

Hot water temperatures required for automatic dishwasher and laundry use can cause scald burns resulting in serious personal injury and/or death. The temperature at which injury occurs varies with the person's age and time of exposure. The slower response time of children, aged or disabled persons increases the hazards to them. Never allow small

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.

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 are needed.

Please contact your A.O. Smith qualified service agent.

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)

Power Distribution Board (PDB)

User Interface Module (UIM)

The MCB contains circuitry for both master control and flame control. Dip switches on the MCB are used to configure the system. The User Interface Module (UIM) communicates with the user through a set of touch pads and a 4-line,20-characterLCD 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

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