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A.O. Smith 500 User's Information Manual
A.O. Smith 500 User's Information Manual

A.O. Smith 500 User's Information Manual

Series 400, 401, 402, 403, 404, 405, 2-stage units
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GAS-FIRED COMMERCIAL
COPPER BOILERS FOR HYDRONIC
HEATING AND HOT WATER SUPPLY
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.
TEXT PRINTED OR OUTLINED IN RED CONTAINS
INFORMATION RELATIVE TO YOUR SAFETY. PLEASE READ
THOROUGHLY BEFORE INSTALLING AND USING THIS
APPLIANCE.
PRINTED IN U.S.A. 0306
CAUTION
PLEASE KEEP THESE INSTRUCTIONS ADJACENT TO BOILER AND
NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.
USER'S INFORMATION MANUAL
GB/GW-300, 400, 500, 650, 750
SERIES 400, 401, 402, 403, 404, 405,
2-STAGE UNITS
Should overheating occur or the gas supply fail to shut off, do
not turn off or disconnect the electrical supply to the pump.
Instead, shut off the gas supply at a location external to the
appliance.
Do not use this boiler if any part has been under water.
Immediately call a qualified service technician to inspect the
boiler and to replace any part of the control system and any
gas control which has been under water.
INDEX
LIGHTING INSTRUCTIONS ....................................... 2-3
MAINTENANCE .......................................................... 3-4
OPERATING SEQUENCE, EMC5000 ......................... 8-14
CONNECTION DIAGRAM ............................................ 13
EMC5000 INSTRUCTIONS ...................................... 14-18
WARRANTY ................................................................. 19
A DIVISION OF A. O. SMITH CORPORATION
MC BEE, SC., RENTON, WA.,
STRATFORD-ONTARIO, VELDHOVEN-THE NETHERLANDS
www.hotwater.com
1
WARNING
WARNING
PART NO. 212132-001
PAGE

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Summary of Contents for A.O. Smith 500

  • Page 1 PLEASE KEEP THESE INSTRUCTIONS ADJACENT TO BOILER AND PRINTED IN U.S.A. 0306 USER'S INFORMATION MANUAL GB/GW-300, 400, 500, 650, 750 SERIES 400, 401, 402, 403, 404, 405, Should overheating occur or the gas supply fail to shut off, do not turn off or disconnect the electrical supply to the pump.
  • Page 2 THE UNIT SHOULD NOT BE INSTALLED DIRECTLY ON A CARPETED FLOOR. A FIRE HAZARD MAY RESULT. Instead, the boiler must be installed on the A. O. Smith Combustible Floor Kit Base or concrete blocks extending beyond the full width and depth of the boiler by at least 3 (76.2mm) inches. If the boiler is installed in a carpeted alcove, the entire floor must be covered with concrete blocks, or use the A.
  • Page 3: Lighting Instructions

    LIGHTING INSTRUCTIONS These models have an automatic hot surface ignition system mounted on the combustion chamber panel inside the front jacket. This hot surface igniter ignites the main burner gas whenever the system control calls for heat. Before proceeding with operation of the unit, make sure the boiler and system are filled with water and all air is expelled from the boiler, radiator tank(s) and piping.
  • Page 4: Burner System

    the surrounding air pressure. Inspection of the boiler and vent system is necessary to insure that flue gas leakage to the surrounding area does not occur. Inspect the external surfaces of the vent system every 3 months for corrosion and leakage. Inspect the vent terminations for corrosion and foreign matter which may be blocking the exhausting flue products.
  • Page 5 Figure 1A. CCB (Drawing #211758)
  • Page 6 Figure 1B. FCB (Drawing #211759)
  • Page 7 Figure 1C. PDB (Drawing #211760)
  • Page 8 closed and everything else is in the proper state, a "call for heat" condition will be initiated. These leads should be shorted together, when a thermostat is not being used. If it is desired that the thermostat control the temperature of the boiler, the operating setpoint of the system should be set higher than the temperature that the thermostat is controlling to.
  • Page 9 Dipswitch configurations are READ ONLY ON POWER UP. These switches are only to be set at the factory or by authorized trained personnel only! Once set at installation they generally remain that way for the duration of the life of the product. If a switch is changed, power must be cycled before the change will take effect.
  • Page 10 • Stored values are recalled from memory. • Configuration dipswitches are read. • Pending faults are recalled • Micros on all boards start running (indicated by a flashing Yellow LED near each micro) • Input sensors are read • Communications between micros and boards is established •...
  • Page 11 The folllowing status information is displayed from this screen: Status Displayed *(True Condition) Outlet temperature too high LW/CO Water Level low Blk Flue Flue blocked Flow Water flowing Low Gas Gas pressure low Tstat Thermostat requesting heat Hi Limit Outlet temp exceeds High Limit setpoint Pump Pump output activated IRI Gas Pwr...
  • Page 12 except the fault states. If enabled the powered vent and the IRI gas valve are turned on. A command is sent to all active stages to cold purge the system. Cold purging clears out any combustion gas that may be in the combustion chamber. When purging is complete the system moves to the Heat State.
  • Page 13 • 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.
  • Page 16 Number of cycles for each stage (Number of times stage has been in heat mode). Kbtu rating of the boiler (0 to 5750Kbtu in 10Kbtu increments) The software revision level of the CCB, and FCB micro- controllers. Current Error Screen: •...
  • Page 17: Troubleshooting Ignition System

    TROUBLESHOOTING IGNITION SYSTEM Fault Messages and Lockout Status (* = stage number: 1 or 2) Fault Displayed Description “Display Fail” Communications with UIM interrupted • Check communication cable to UIM. Try moving to other Internal Communications connector on CCB. Also check the connectors where the cable is plugged in for best connecting wires.
  • Page 18 “Blocked Flue” Flue is Blocked • Caused by the blocked flue switch contacts being open when they should have been closed. Check for flue blockage, switch contacts, wiring. “High Limit” Outlet temp. exceeded high limit setpoint • Caused when the temperature of the outlet probe exceeds the high limit setpoint. This is an internal “software”...
  • Page 19 Other troubleshooting hints: 1. Input switches can be easily checked by observing their activation on the UIM System Status screen. Force the boiler to remain in the Standby mode by opening the Thermostat input or by setting the operating setpoint to the minimum so that the system does not request heat.
  • Page 20 NOTES...
  • Page 21 NOTES...
  • Page 22 NOTES...
  • Page 23 If this is not practical, the owner should contact: U.S. Customers A. O. Smith Water Products Company 500 Tennessee Waltz Parkway, Ashland City, TN 37015 Telephone: 800 323-2636 The warrantor will only honor replacement with identical or similar parts thereof which are manufactured or distributed by the warrantor.
  • Page 24 A DIVISION OF A. O. SMITH CORPORATION MC BEE, SC., RENTON, WA., STRATFORD-ONTARIO, VELDHOVEN-THE NETHERLANDS www.hotwater.com...