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500 Tennessee Waltz Parkway
Ashland City, TN 37015
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 0710
INSTRUCTION MANUAL
MODELS:
VB/VW 1500, 2000
SERIES 100/101
500 Tennessee Waltz Parkway
Ashland City, TN 37015
www.hotwater.com
1
317294-000
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Troubleshooting
Related Manuals for A.O. Smith VB/VW 1500, 2000
Summary of Contents for A.O. Smith VB/VW 1500, 2000
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Page 1: Limited Warranty
Ashland City, TN 37015 INSTRUCTION MANUAL GAS-FIRED COPPER BOILERS FOR HYDRONIC HEATING AND HOT WATER SUPPLY MODELS: • Installation VB/VW 1500, 2000 • Operation SERIES 100/101 • 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. -
Page 2: Table Of Contents
TABLE OF CONTENTS Vertical Installation Requirements ..........18 TABLE OF CONTENTS ...............2 SAFE INSTALLATION, USE, AND SERVICE ........3 Horizontal Installation Requirements ........18 APPROVALS ..................3 Direct Vent Installation Requirements ........18 GENERAL SAFETY................4-5 Installation Requirements for the Commonwealth of Mass ..20 INTRODUCTION ..................6 SYSTEM INSTALLATION .............. -
Page 3: 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 4: General Safety
GENERAL SAFETY Breathing Hazard - Carbon Monoxide Gas Special consideration must be taken with installation above 4500 feet. Please contact an A. O. 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 levels of carbon monoxide gas... -
Page 5: General Safety
GENERAL SAFETY GROUNDING INSTRUCTIONS supplier or service agent. Keep area clear until a service call has been made. This boiler must be grounded in accordance with the National Electrical At times you may not be able to smell an LP gas leak. One cause Code, Canadian Electrical Code and/or local codes. -
Page 6: Introduction
INTRODUCTION this manual and the local code authority having jurisdiction. This design complies with the current edition of the ANSI These should be carefully followed in all cases. Authorities Z21.13 - CSA 4.9 Standard for Gas Fired Low Pressure Steam having jurisdiction should be consulted before installation and Hot Water Boilers. - Page 7 TABLE 1. GAS AND ELECTRICAL CHARACTERISTICS Manifold Pressure Maximum Supply Pressure Minimum Supply Pressure Models Type of Gas Inches W.C. Inches W.C. Inches W.C. VB/VW-1500,2000 Natural -.2 to - 4.9 -.04 to - 1.22 14.0 3.49 VB/VW-1500,2000 Propane -.2 to - 4.9 -.04 to - 1.22 14.0 3.49...
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Page 8: Capacity And Flow Data
CAPACITY AND FLOW DATA TABLE 3. RECOVERY CAPACITIES Temperature Rise - ΔT °F (°C) Input Output Model Water Rating Rating Flow (Btu/hr) (Btu/hr) (11) (22) (33) (44) (50) (56) (67) (78) 7,560 3,780 2,520 1,890 1,680 1,512 1,260 1,080 VW-1500 1,500,000 1,260,000 28,615... -
Page 9: Low Gas Switch
LOW GAS SWITCH FLOW SWITCH The flow switch pictured in figure 6 activates when sufficient flow This VF boiler is available with a low gas pressure switch which has been established. Switch will not close when flow is restricted meets the CSD-1 code requirements, see Figure 5. or is not present The Low Gas Pressure Switch (LGPS) is normally closed and remains closed unless the pressure falls below the preset pressure. -
Page 10: 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”... -
Page 11: General
The Discharge Pipe: This ASME-rated valve has a discharge capacity that exceeds maximum boiler input rating and a pres sure rating that does not exceed maxi- • Should not be smaller in size than the outlet pipe size of the mum working pres sure shown on boiler rating plate. -
Page 12: Panels And Covers
boiler is approved for installation on combusti b le flooring in an 3. In so far as is practical, close all building doors and windows alcove with minimum clearances to combustibles of: and all doors between the space in which the appliances remaining connected to the common venting system are 12” (305mm) Rear; 4” (102mm) Top and Sides; 6” (152mm) Vent. located and other spaces of the building. -
Page 13: Fresh Air Openings For Confined Spaces
air to the confined space and the total Btu/hr input rating of all The confined space should be provided with two permanent appliances installed in the space. 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. -
Page 14: Outdoor Air Through Two Vertical Ducts
The confined space should be provided with two permanent the top and one commencing within 12 inches (300 mm) of the horizontal ducts, one commencing within 12 inches (300 mm) of bottom of the enclosure. The vertical ducts should communicate the top and one commencing within 12 inches (300 mm) of the directly with the outdoors. -
Page 15: 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 16: 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 17: Venting
VENTING 3. Horizontal Direct Vent - using TWT to exhaust flue prod- ucts and PVC piping to bring combus tion air to the boiler from the outside, see Figures 12 and 12C. 4. 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. -
Page 18: Venting Supports
VENTING SUPPORTS location based on the dimensions shown in Figure 9G. Do not locate the terminal within 8 feet (2.5m) of an inside corner Care must be taken in the installation of the venting system of a building or adjacent to outside walls, shrubs or other that adequate support is maintained throughout the installation such objects that may cause adverse wind conditions in the process. - Page 19 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 20: Installation Requirements For The Commonwealth Of Mass
2. The AIT should not be located less than 3 feet (1.0m) IMPORTANT below any exhaust vent within 10 feet (3.0m), see “ H O R I Z O N TA L I N S TA L L AT I O N R E Q U I R E M E N T S ” The labels in the Direct Vent Kit must be affixed to the boiler sec tion. - Page 21 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 22 Option B (Figures 11B & 11C) 70 EQUIVALENT FEET (27.4m) assures no recirculation of flue gases. OF VENTING (MAX.) AL 29-4C ® AIR INTAKE TERMINAL HORIZONTAL AIR INTAKE NOTES: • IF THE EXHAUST VENT TERMINAL IS WITHIN 10’ (3.0m) PVC PIPE 70 OF A WALL OR A PARAPET, IT MIUST EXTEND A MINIMUM EQUIVALENT FEET (27.4m) OF 2’...
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Page 23: System Installation
SYSTEM INSTALLATION An air separator as shown in the piping diagrams GENERAL is recom mended especially for modern commercial hydronic systems. 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 3. -
Page 24: Internal Contaminants
8. PRIMARY SYSTEM CONTROL the designated temperature control opening on the storage tank, All VF boiler installations require a “Primary System Control” that typically a 3/4 inch NPT opening in the lower portion of the tank. senses and reacts to water temperature inside the storage tank On hydronic heating applications the probe being used must be on domestic water applications or in the return line on primary/ installed in the return line of the primary hydronic heating loop... -
Page 25: Hard Water Conditions
It is essential that all water piping be installed and connected type regulator must be installed in gas supply line. For proper as shown on the diagrams. Check the diagrams to be used gas regulation the lock-up style regulators must be installed no closer than a minimum of 2 feet from the boiler and a maximum thoroughly before starting installation to avoid possible errors of 7 feet away from the boiler. -
Page 26: Field Wiring
Z223.1/NFPA 54 or the Natural Gas and Propane Installation present by performing the three voltage tests below. Refer to Figure Code, CAN/CSA B149.1 12D for these tests. • Table 7 is based on a pressure drop of 0.5 inches water column Confirm RMS voltage between: (0.124kPa), and a gas with a specific gravity of 0.60 and a heating •... -
Page 31: Schematic Diagram
VB/VW 1500/2000 SCHEMATIC DIAGRAM NEUTRAL VB/VW 1500/2000 SCHEMATIC DIAGRAM 120VAC 120VAC RTN POWER POWER RELAY ON/OFF SWITCH CIRCULATING PUMP RELAY COIL CONTACTS (VW UNITS ONLY) PUMP RELAY CONTACTS 20 AMP FUSE (PDB – F2) K8 (MCB-II) PUMP RELAY COIL 10 AMP FUSE (PDB – F6) K11 (MCB-II) IGNITER GAS VALVE... -
Page 32: Blocked Inlet
CIRCUIT BOARD JUMPERS VB/VW 1500/2000 W MCB-II – JP1 (not used), JP2 (used – 2.7A igniter), JP3 & JP4 (used – removed for hipot test). PDB – JP1 (used – run selection, JP2 & JP3 (used – removed for hipot test). MCB-II DETAIL A MCB-II DETAIL B TRAN... -
Page 33: Wiring Diagram
0 WIRING DIAGRAM LEGEND 120VAC WIRING LOW VOLTAGE WIRING CAT-5 COMM CABLE TRANSFORMER AVAILABLE OPTION 120/24 VAC 24VAC USER INTERFACE MODULE NOTE1: IF ANY OF THE ORIGINAL WIRE AS SUPPLIED CAT-5 CABLE WITH THE APPLIANCE MUST BE REPLACED, REPLACE (UIM) WITH EQUIVALNET GAUGE WIRE, INSULATION TYPE 105°C, 600 VOLTS. -
Page 34: Operation
OPERATION IMPORTANT Only a Certified Start-up agent should perform the initial firing of the boiler. At this time the user should not hesitate to ask the start-up technician any questions regarding the operation and maintenance of the unit. If you still have questions, please contact the factory or your local A.O. -
Page 35: 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 36: Lighting And Operating Instructions
LIGHTING AND OPERATING INSTRUCTIONS... -
Page 37: Adjustment
ADJUSTMENT LOW FIRE SETTING NATURAL GAS 7.5 - 9.5% CO PROPANE 9.5 - 12.0% 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: when flame is detected on the burner. If the flame rod is missing Temperature probes (MCB - outlet and either inlet or tank are or shorted, the flame will not be detected. required): The MCB accepts analog temperature inputs from OUTPUTS FROM MCB up to three sensors (inlet, outlet, and tank). RELAY CONTACT OUTPUT: Manual Reset High Limit (MCB - required): The MRHL or manual Alarm (MCB - 24VAC - optional): Provides electrical power to... -
Page 39: Operating Sequence
MCB - Three position Dipswitch SW2: This dipswitch is similar to the FCB dipswitches described below, 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. Dipswitch Function Dipswitch Position SW2 P1: Spare: NOT USED NOT USED... - Page 40 • Temperature Screen: selected post-circulate time to cycle the hot water out of the Displays the sensed temperatures of the Outlet, Inlet, and boiler. The FCB is commanded to shut down and the Alarm Tank probes. Also displayed is the calculated Delta T (Outlet output is turned on.
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Page 41: Operating Setpoint Adjustment Procedure
2. Scroll the “>” with the DOWN key next to USER SETTING SCREEN. this state until the MCB sends a command to clear the error, and the system returns to the idle state. 3. Press the SELECT key. 4. Scroll the “>” with the DOWN key until it is pointing to HIGH • Cold Purge State Cold purge occurs when the MCB micro commands the LIMIT SETPOINT. - Page 42 The software revision level of the MCB. From the Current Error Screen this key is used to reset the • Current Error Screen: system from an error: Displays the last error that the system has detected plus • Up and Down Keys: a time stamp of when the error occurred. (The time stamp These keys are used to move upwards and downwards in is based on the elapsed hours value at the time the error occurred.
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Page 43: 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. “Blocked Intake”... -
Page 44: 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 45: Relief Valve
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. -
Page 46: Venting Maintenance
HEAT EXCHANGER PREVENTIVE 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 MAINTENANCE include a sag or low spot in the line will also form a condensate trap In most water supply systems solids exist. -
Page 47: 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 should prove upon examination by the warrantor to be defective in material 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. - Page 48 500 Tennessee Waltz Parkway, Ashland City, TN 37015 Technical Support: 800-527-1953 • Parts: 800-433-2545 • Fax: 800-644-9306 www.hotwater.com...