A.O. Smith VB-500, VB-750 Instruction Manual
Series 200/201 gas-fired copper boilers for hydronic heating and hot water supply
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Also See for VB-500, VB-750:
- User manual (24 pages) ,
- Service handbook (74 pages) ,
- Service parts (8 pages)
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GAS-FIRED COPPER BOILERS FOR
HYDRONIC HEATING AND HOT WATER SUPPLY
• Installation
• Operation
• Maintenance
• 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.
PRINTED 0911
INSTRUCTION MANUAL
MODELS:
VB/VW-500, 750 AND 1000
SERIES 200/201
MC BEE, SC., RENTON, WA.,
STRATFORD-ONTARIO, VELDHOVEN-THE NETHERLANDS,
NANJING, CHINA
www.hotwater.com / email: parts@hotwater.com
1
320856-001
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Table of Contents
Troubleshooting
Related Manuals for A.O. Smith VB-500, VB-750
Summary of Contents for A.O. Smith VB-500, VB-750
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Page 1: Limited Warranty
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 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. -
Page 2: Safe Installation, Use And Service
SAFE INSTALLATION, USE AND SERVICE The proper installation, 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. -
Page 3: General Safety
GENERAL SAFETY... -
Page 4: Dimension And Capacity Data
DIMENSION AND CAPACITY DATA Minimum clearances to combustibles: • 4” (102mm) rear • 0” (0mm) top & sides • 6” (152mm) vent FIGURE 1. TABLE 1. - GAS AND ELECTRICAL CHARACTERISTICS Manifold Pressure Maximum Supply Pressure Minimum Supply Pressure Model Type of Gas Inches W.C. Inches W.C. Inches W.C. VB/VW-500, 750, 1000 NATURAL -2 to -3.5 -.5 to .9... -
Page 5: Capacity And Flow Data
CAPACITY AND FLOW DATA TABLE 3. RECOVERY CAPACITIES. Temperature Rise - °F (°C) Input Output Model Water Rating Rating Flow Btu/hr Btu/hr (22) (33) (44) (90) (56) (67) (78) 1,268 VW-500 500,000 421,500 4,797 3,198 2,399 2,132 1,919 1,599 1,371 1,901 1,268 VW-700 750,000 633,750 7,196 4,797... -
Page 6: Table Of Contents
CONTENTS SAFE INSTALLATION, USE AND SERVICE ...........2 Horizontal Installtion Requirements ............17 GENERAL SAFETY..................3 Direct Vent Installation Requirements ..........19 DIMENSION AND CAPACITY DATA ............4 INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF CAPACITY AND FLOW DATA ..............5 MASSACHUSETTS ..................19 CONTENTS ....................6 SYSTEM INSTALLATION ................22 INTRODUCTION ...................6 General ....................22 Grounding Instructions ................7... -
Page 7: Grounding Instructions
GROUNDING INSTRUCTIONS doors open to ventilate, then call your gas supplier or service agent. Keep area clear until a service call has This boiler must be grounded in accordance with the National been made. Electrical Code and/or local codes. Boiler is polarity sensitive; correct wiring is imperative for proper operation. -
Page 8: Figure
CONTROL COMPONENTS THE CONTROL SYSTEM flue of the unit is restricted or blocked. The BFS is a normally closed switch that opens when positive pressure is placed on the switch because of any restriction to the exhaust venting. If the BFS is The control system consists of four basic components: activated check and clear any obstructions causing the restriction. 1) Modulation Control Board (MCB); 2) Power Distribution Board (PDB); 3) Variable Frequency Drive (VFD), see Figure LOW GAS SWITCH... -
Page 9: Water Temperature Limit Controls
Temperature Probe allows a boiler to sense the actual water WATER TEMPERATURE LIMIT CONTROLS 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 Probe as the “Tank” temperature on the default Temperatures screen. -
Page 10: General
The Discharge Pipe: This ASME-rated valve has a discharge capacity that exceeds maximum • Shall not be smaller in size than the outlet pipe size of the valve, or boiler input rating and a pres sure rating that does not exceed maximum have any reducing couplings or other restrictions. -
Page 11: Chemical Vapor Corrosion
UNCONFINED SPACE In buildings of conventional frame, brick or stone construction, unconfined spaces may provide adequate air for com b ustion. If the unconfined space is within a build i ng of tight construction (build i ngs using the following construction: weath e r strip p ing, heavy insulation, caulk i ng, vapor barrier, etc.), air for com b us t ion, venti lation, and draft hood di lu tion must be obtained from outdoors or spaces freely communicating with the outdoors. -
Page 12: Outdoor Air Through Two Openings
OUTDOOR AIR THROUGH TWO HORIzONTAL DUCTS 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 18 for complete venting installation instructions. OUTDOOR AIR THROUGH TWO OPENINGS FIGURE 9C. -
Page 13: Air From Other Indoor Spaces
AIR FROM OTHER INDOOR SPACES 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. -
Page 14: Termination Clearances Sidewall Power Vent
TERMINATION CLEARANCES SIDEWALL POWER VENT POWER VENT (using room air for combustion) EXTERIOR CLEARANCES FOR SIDEWALL VENT TERMINATION F IX E D C L O S E D O P E R A B L F IX E D C L O S E D O P E R A B L VENT TERMINAL AIR SUPPLY INLET... -
Page 15: Termination Clearances Sidewall Direct Vent
TERMINATION CLEARANCES SIDEWALL DIRECT VENT DIRECT VENT (using outdoor air for combustion) EXTERIOR CLEARANCES FOR SIDEWALL VENT TERMINATION F IX E D C L O S E D O P E R A B L F IX E D C L O S E D O P E R A B L VENT TERMINAL AIR SUPPLY INLET... -
Page 16: Venting
VENTING 2. Through-the-Wall Termination (TWT) - hori zontal vent termination directly through an outside wall, see Figure 11A. 3. Horizontal Direct Vent - using TWT to exhaust flue prod u cts and PVC piping to bring combus tion air to the boiler from the outside, see Figures 12 and 12C. 4. -
Page 17: Venting Supports
This is especially true in colder 12C for differences between standard and direct vent installations. climates where ice buildup is likely to occur. A.O. Smith Corporation will not be held liable for any personal injury 3. An AL 29-C Vent Vertical Vent Terminal must be used at ®... - Page 18 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. Joints are not joined to show vent pipe orientation. FIGURE 11. VERTICAL TERMINATION. NOTES: Joints are not joined to show vent pipe orientation.
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Page 19: Direct Vent Installation Requirements
1. The Air-Intake System (AIS) must ter m inate with the venting DIRECT VENT INSTALLATION REQUIREMENTS equipment pro vided with the boiler, Refer to the parts list for required direct vent parts. Follow the guidelines in the “HORIZONTAL INSTALLATION REQUIREMENTS” section for the exhausting of flue 2. The AIT shall not be located less than 3 feet (1.0m) below products. - Page 20 NOTE: Joints are not joined to show vent pipe orientation. 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.
- Page 21 Option B (Figures 12B & 12C) assures no recirculation of flue gases. 70 EQUIVALENT FEET (27.4m) OF VENTING (MAX.) AL 29-4C ® AIR INTAKE TERMINAL HORIzONTAL AIR INTAKE NOTES: 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’...
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Page 22: System Installation
SYSTEM INSTALLATION related to the total water volume of the system. Refer GENERAL to “Systems and Equipment” volume of the ASHRAE handbook. If the system is to be filled with water for testing or other purposes during cold weather and before actual operation, An air separator as shown in the piping diagrams is recom- care must be taken to prevent a downdraft entering the boiler mended especially for modern commercial hydronic systems. -
Page 23: Internal Contaminants
HOT WATER SUPPLY BOILER SYSTEM - GENERAL 7. SYSTEM CONTROLLER WATER LINE CONNECTIONS 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 This section provides detailed installation diagrams for a temperature thermostat(s). Multiple boiler installations are typical method of application for the unit. -
Page 24: Gas Connections
This is accomplished by changing two dipswitch settings on the When local codes require a main manual shut-off valve MCB. First, dipswitch “4” must be set to the “ON” position to outside the boiler jacket, a suitable main manual shut-off valve designate the remote probe as the controlling probe. -
Page 28: Wiring
WIRING 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*** Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. -
Page 29: Suggested Pipe Sizing Tables
SUGGESTED PIPE SIzING TABLES... -
Page 30: Wiring Diagram
WIRING DIAGRAM... -
Page 32: Vb/Vw-500, 750 & 1000 Schematic Diagram
VB/VW-500, 750 & 1000 SCHEMATIC DIAGRAM FIGURE 18. - SCHEMATIC DIAGRAM... -
Page 33: Operation
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. -
Page 34: Water Temperature Regulation
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. - Page 35 MCB - 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.
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Page 36: Lighting & Operation Instructions
LIGHTING & OPERATION INSTRUCTIONS FOR MODELS VB/VW 500, 750 AND 1000:... -
Page 37: Adjustment
ADJUSTMENT 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 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. -
Page 38: Inputs To Mcb
INPUTS TO MCB FLAME SENSOR: Flame (MCB - required): Returns a signal to the microprocessor TEMPERATURE SENSORS: if flame is detected on the burner. If the flame rod is missing or Temperature probes (MCB - outlet and either inlet or tank are shorted, the flame will not be detected. required): The MCB accepts analog temperature inputs from up to three sensors (inlet, outlet, and tank). OUTPUTS FROM MCB MRHL (Manual Reset HIGH LIMIT): The MRHL is a hi-limit switch RELAY CONTACT OUTPUT: located inside the outlet probe. It is a normally closed switch that Alarm (MCB - 24VAC - optional): Provides electrical power to opens if the probe is exposed to a temperature higher than the trip operate an external alarm. This can be an audio device (i.e.,... -
Page 39: Operating Sequence
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. -
Page 40: Water
UIM OPERATING PROCEDURES 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. -
Page 41: Operating Setpoint Adjustment Procedure
The process waits in this state until the call for heat is satisfied, the • Cold Purge State thermostat input is opened, or a fault occurs. When heat is satisfied, Cold purge occurs when the MCB micro commands the the sequence continues to Post-Purge and then back to Idle. If blower to go on before lighting to clear the unit of residual three tries for ignition has been selected on the MCB dipswitch and gases. -
Page 42: High Limit Differential Setpoint Adjustment Procedure
Elapsed hours of operation (Total time system has been powered up) Use the following procedure to change the automatically resettable High Limit Setpoint: Number of running minutes (Number of minutes system has been in the run mode) 1. Press the MENU key. kBtu rating of the boiler (0 to 5750kBtu in 10kBtu increments) 2. Scroll the “>” with the DOWN key next to USER SETTING SCREEN. The software revision level of the MCB. 3. Press the SELECT key. • Current Error Screen: 4. Scroll the “>” with the DOWN key until it is pointing to HIGH LIMIT SETPOINT. - Page 43 • Up and Down Keys: has been detected and the system has stopped running. It is on continuously for soft faults and flashes for hard These keys are used to move upwards and downwards in faults. The Yellow LED indicates that the boiler is in a screens to reach a desired item and to change setpoints ready mode waiting for a call for heat command.
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Page 44: Troubleshooting Ignition System
TROUBLESHOOTING IGNITION SYSTEM Fault Messages and Lockout Status (* = stage number: 1, 2, 3, or 4) FAULT DISPLAYED DESCRIPTION RED LED LOCKOUT “Display Fail” 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. “Comm. -
Page 45: Troubleshooting Gas Valve
Problem: Gas OK, no burner start up (both shutoff valves are TROUBLESHOOTING GAS VALVE open, fan turns) There is not enough gas to accommodate a start up. Turn throttle Problem: Non-linear CO curve on adjusted boiler (deviation screw ½ turn counterclockwise and try to start again with more more than 3-6%) gas. -
Page 46: Relief Valve
or on the blower and motor. Buildups of dirt and lint on the blower and motor can create excessive 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. -
Page 47: Venting Maintenance
HEAT EXCHANGER PREVENTATIVE MAINTENANCE lines with air or water and clear or replace the blocked portions of the line as necessary. Note that areas of the drain line which In most water supply systems solids exist. As the water is heated, these include a sag or low spot in the line will also form a condensate trap tend to drop out depositing as scale or lime. -
Page 48: Notes
NOTES... - Page 49 NOTES...
- Page 50 NOTES...
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Page 51: Limited Warranty
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. - Page 52 500 Tennessee Waltz Parkway, Ashland City, TN 37015 Phone: 800-433-2545 www.hotwater.com E-Mail: parts@hotwater.com...