A.O. Smith VB-VW-500, VB-VW-750, VB-VW-1000 User Manual

GAS-FIRED POWER BURNER

COPPER BOILERS FOR HYDRONIC HEATING

AND HOT WATER SUPPLY

USER’S MANUAL

• Installation

• Operation

• Maintenance

• Limited W arranty

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.

— WHA T 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.

MODELS:

VB/VW-500, 750 AND 1000

SERIES 100/101

— Installation and service must be

performed by a qualified installer,

service agency or the gas supplier.

MC BEE, SC., RENTON, WA.,

STRATFORD-ONTARIO, VELDHOVEN-THE NETHERLANDS,

NANJING, CHINA

ww w.hotwater.com / email: parts@hotwater.com

PRINTED 0207 212801-000

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-related messages 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.

IMPORT ANT 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.

GENERAL SAFETY

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 .......................................................................................................................................................................... 23

INTRODUCTION

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

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

void if the boiler(s) have been

AL 29-4C 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.

is a registered trademark of Allegheny Ludlum

INST ALLATION 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-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 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 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 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.

CONNECTION DIAGRAM

VB/VW-500, 750 & 1000 SCHEMATIC DIAGRAM

SCHEMA TIC DIAGRAM

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