GAS-FIRED COPPER BOILERS FOR
HYDRONIC HEATING AND HOT WATER SUPPLY
INSTRUCTION MANUAL
MODELS:
VB/VW-500, 750 AND 1000
SERIES 200/201
• 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.
MC BEE, SC., RENTON, WA.,
STRATFORD-ONTARIO, VELDHOVEN-THE NETHERLANDS,
NANJING, CHINA
PRINTED 0911
320856-001
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. 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.
This is the safety alert symbol. It is used to alert you to
potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible
injury or death.
DANGER indicates an imminently
hazardous situation which, if not avoided,
will result in injury or death.
DANGER
WARNING indicates a potentially hazardous
situation which, if not avoided, could result
in injury or death.
WARNING
CAUTION indicates a potentially hazardous
situation which, if not avoided, could result in
minor or moderate injury.
CAUTION
CAUTION used without the safety alert
symbol indicates a potentially hazardous
CAUTION
situation which, if not avoided, could result in
property damage.
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.
The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances known
to the State of California to cause cancer, birth defects, or other reproductive harm, and requires businesses to warn of potential
exposure to such substances.
This product contains a chemical known to the State of California to cause cancer, birth defects, or other reproductive harm. This
appliance can cause low level exposure to some of the substances listed in the Act.
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.
2
GENERAL SAFETY
3
DIMENSION AND CAPACITY DATA
• 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
NATURAL
PROPANE
Inches W.C.
-2 to -3.5
kPa
Inches W.C.
kPa
3.44
3.44
Inches W.C.
kPa
2.0
2.0
VB/VW-500, 750, 1000
VB/VW-500, 750, 1000
-.5 to .9
-.5 to .9
14
14
4.0
8.0
-2 to -3.5
Minimum Pressures must be maintained during all operating conditions.
Electrical Power: 120v, 60hz, and 30 amps.
TABLE 2. - ROUGH-IN DIMENSIONS
Models
VB/VW-500
inches
VB/VW-750
VB/VW-1000
Dimensions
mm
152
102
inches
mm
152
102
inches
mm
Flue Outlet Diameter
6
4
6
4
6
4
152
102
Air Intake Diameter
Water Inlet
2” NPT
2” NPT
1” NPT
Water Outlet
Gas Inlet
A
B
C
D
E
F
56
30
1422
762
762
1143
914
419
203
381
229
292
279
267
838
787
62
30
1575
762
762
1295
1067
419
203
381
229
292
279
267
838
787
71
30
1803
762
762
1499
1219
419
203
381
229
292
279
267
838
787
30
30
30
45
51
59
36
42
48
16.5
8
16.5
8
16.5
8
G
H
J
15
15
15
9
9
9
K
L
11.5
11
11.5
11
11.5
11
M
N
P
10.5
33
10.5
33
10.5
33
31
31
31
4
CAPACITY AND FLOW DATA
TABLE 3. RECOVERY CAPACITIES.
Temperature Rise - °F (°C)
Input
Rating
Btu/hr
Output
Rating
Btu/hr
Model
No.
Water
Flow
40
(22)
60
(33)
80
90
100
(56)
120
(67)
140
(78)
(44)
(90)
GPH
LPH
GPH
LPH
GPH
LPH
1,268
4,797
1,901
7,196
2,535
9,595
845
634
2,399
951
3,598
1,268
4,797
563
2,132
845
3,198
1,127
4,264
507
1,919
761
2,878
1,014
3,838
423
1,599
634
2,399
845
3,198
362
1,371
543
2,056
724
2,741
VW-500
VW-700
VW-1000
500,000
750,000
421,500
633,750
845,000
3,198
1,268
4,797
1,690
6,397
1,000,000
TABLE 4. PUMPING PERFORMANCE GUIDE.
VB MODELS - FLOW, HEAD LOSS AND TEMPERATURE RISE
40F° (22°C) Maximum Flow Rate Minimum Flow Rate
MODEL GPM LPH P FT P m GPM LPH P FT P m GPM LPH P FT P m GPM LPH PFT Pm T °F T°C GPM LPH P FT P m T °F T °C
20F° (11°C)
t
30F° (17°C)
t
t
VB-500 42 159 1.8 0.5
VB-750 63 238 2.9 0.9
VB-1000 85 322 3.9 1.2
28 106 1.3
42 159 2.1
56 212 2.8
0.4 21 79 1.0 0.3 100 379 3.8 1.2
8
4
7
8
21 79 1.0 0.3 40 22
32 121 1.8 0.5 40 22
42 159 2.3 0.7 40 22
0.6 32 121 1.8 0.5 110 416 4.3 1.3 12
0.9 42 159 2.3 0.7 120 454 4.9 1.5 14
5
CONTENTS
SAFE INSTALLATION, USE AND SERVICE ...........................................2
GENERAL SAFETY......................................................................................3
DIMENSION AND CAPACITY DATA .........................................................4
Horizontal Installtion Requirements......................................................17
Direct Vent Installation Requirements .................................................19
INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF
CAPACITY AND FLOW DATA....................................................................5 MASSACHUSETTS.....................................................................................19
CONTENTS...................................................................................................6 SYSTEM INSTALLATION ..........................................................................22
INTRODUCTION...........................................................................................6
Grounding Instructions.............................................................................7
Inlet Water Considerations......................................................................7
Correct Gas..............................................................................................7
Precautions ...............................................................................................7
Liquefied Petroleum Gas Models ..........................................................7
High Altitude Installations........................................................................7
Field Installed Components....................................................................7
CONTROL COMPONENTS.........................................................................8
The Control System................................................................................8
General....................................................................................................22
Hot Water Heating (Hydronic) Equipment..........................................22
Internal Contaminants............................................................................23
Hot Water Supply Boiler System - General Water Line Connections...23
Hard Water Conditions..........................................................................23
Thermal Expansion (Closed System)..................................................23
Remote Probe Installation Procedure .................................................23
Gas Connections ...................................................................................24
Gas Supply Line Sizing........................................................................24
Wiring ......................................................................................................28
Hot Surface Igniter..................................................................................8 SUGGESTED PIPE SIZING TABLES .....................................................29
Pressure Switches ...................................................................................8 WIRING DIAGRAM ....................................................................................30
Low Gas Switch ......................................................................................8 VB/VW-500, 750 & 1000 SCHEMATIC DIAGRAM ...............................32
Water Flow Switch ..................................................................................8 OPERATION................................................................................................33
Flame Sensor...........................................................................................8
Water Temperature Limit Controls.........................................................9
ON/OFF Switch........................................................................................9
Circulating Pump......................................................................................9
Temperature Probes ................................................................................9
Low Water Cutoff (Optional) ..................................................................9
Pressure Relief Valve..............................................................................9
Important .................................................................................................33
General....................................................................................................33
Filling and Purging of Heating Boiler Installation..............................33
Filling Hot Water Supply Boiler Installation .......................................33
Purging Gas Line ..................................................................................33
Inlet Gas Pressure ................................................................................33
Water Temperature Regulation.............................................................34
GENERAL....................................................................................................10 LIGHTING & OPERATION INSTRUCTIONS..........................................36
Required Ability ......................................................................................10
Location...................................................................................................10
Panels and Covers................................................................................10
Chemical Vapor Corrosion.................................................................... 11
Installtion Clearances............................................................................. 11
Leveling...................................................................................................11
Air Requirements ................................................................................... 11
Unconfined Space..................................................................................11
Adjustment ..............................................................................................37
Setting of the Test Mode.....................................................................37
Control System.......................................................................................37
Inputs to MCB .......................................................................................38
Operating Sequence..............................................................................39
UIM Operating Procedures...................................................................40
Operating Setpoint Adjustment Procedure..........................................41
High Limit Differential Setpoint Adjustment Procedure.....................42
Confined Space .....................................................................................11 TROUBLESHOOTING IGNITION SYSTEM ............................................44
Fresh Air Openings for Confined Spaces.......................................... 11
Outdoor Air Through Two Openings...................................................12
Troubleshooting Gas Valve...................................................................45
Main Burner............................................................................................45
Outdoor Air Through One Opening ....................................................12 PREVENTATIVE MAINTENANCE.............................................................45
Outdoor Air Through Two Horizontal Ducts.......................................12
Outdoor Air Through Two Vertical Ducts...........................................12
Air From Other Indoor Spaces............................................................13
Termination Clearances Sidewall Power Vent ...................................14
Termination Clearances Sidewall Direct Vent ....................................15
VENTING.....................................................................................................16
Special Installation Considerations.......................................................16
Venting System Using AL 29-4C®.......................................................16
General Exhaust Vent Installation Procedure ....................................16
Connecting Vent to Boiler ....................................................................16
Relief Valve ............................................................................................46
Combustion Air Filter.............................................................................46
Blower Compartment.............................................................................46
Burner Maintenance...............................................................................46
Condensate Removal System..............................................................46
Venting Maintenance .............................................................................47
Heat Exchanger Preventative Maintenance........................................47
Deliming ..................................................................................................47
Tube Cleaning Procedure Mechanical Removal of Deposits..........47
Replacement Parts ................................................................................47
Venting Supports....................................................................................17 NOTES.........................................................................................................48
Vertical Installation Requirements ........................................................17 LIMITED WARRANTY................................................................................51
INTRODUCTION
AL 29-4C® is a registered trademark of Allegheny Ludlum
Corporation.
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.
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
Detailed installation diagrams are found in this manual. These followed in all cases. Authorities having jurisdiction should be
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.
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
The factory warranty will be void if the boiler(s) have been
improperly installed or operated.
National Electric Code, NFPA 70.
6
doors open to ventilate, then call your gas supplier or
service agent. Keep area clear until a service call has
been made.
GROUNDING INSTRUCTIONS
This boiler must be grounded in accordance with the National
Electrical Code and/or local codes. Boiler is polarity sensitive;
correct wiring is imperative for proper operation.
At times you may not be able to smell an LP gas leak.
One cause is odor fade, which is a loss of the chemical
odorant that gives LP gas its distinctive smell. Another
cause can be your physical condition, such as having
a cold or diminishing sense of smell with age. For
these reasons, the use of a propane gas detector is
recommended.
This boiler must be connected to a grounded metal, permanent
wiring system, or an equipment grounding conductor must be
run with the circuit conductors and connected to the equipment
grounding terminal or lead on the boiler.
INLET WATER CONSIDERATIONS
IF YOU EXPERIENCE AN OUT OF GAS SITUATION, DO
NOT TRY TO RELIGHT APPLIANCES YOURSELF. Call
your local service agent. Only trained LP professionals
should conduct the required safety checks in accordance
with industry standards.
To minimize the amount of condensate, a minimum inlet
water temperature to the heat exchanger of 120°F (49°C)
shall be maintained. This temperature can be acquired by
returning 120°F (49°C) water from the remote storage tank to
the boiler or by installing a by-pass loop between the boiler’s
inlet and outlet connections. When installing a by-pass loop, a
remote probe MUST be used, see SYSTEM INSTALLATION.
HIGH ALTITUDE INSTALLATIONS
Circulating water through the boiler and to the remote storage
tank (if applicable) is accomplished by a pump on VW models
only. For hot water heating systems using the VB model,
the circulating pump is NOT provided on standard models
(optional) and must be field installed.
CORRECT GAS
MAKE SURE THE GAS ON WHICH THE BOILER WILL
OPERATE IS THE SAME AS THAT SPECIFIED ON THE
BOILER RATING PLATE. DO NOT INSTALL THE BOILER
IF EQUIPPED FOR A DIFFERENT TYPE OF GAS — CON-
SULT YOUR SUPPLIER.
PRECAUTIONS
IF THE UNIT IS EXPOSED TO THE FOLLOWING, DO
NOT OPERATE UNTIL ALL CORRECTIVE STEPS HAVE
BEEN MADE BY A QUALIFIED SERVICE AGENT:
1. EXPOSURE TO FIRE.
2. IF DAMAGED.
Rated inputs are suitable up to 7000 feet (2134m)
elevation. Consult the factory for installation at altitudes
over 7000 feet (2134m).
3. FIRING WITHOUT WATER.
4. SOOTING.
FIELD INSTALLED COMPONENTS
When installing the boiler, the following components
MUST be installed:
IF THE BOILER HAS BEEN EXPOSED TO FLOODING,
IT MUST BE REPLACED.
1) Circulating Pump (Hydronic)
LIQUEFIED PETROLEUM GAS MODELS
Boilers for propane or liquefied petroleum gas (LPG) are
different from natural gas models. A natural gas boiler will not
function safely on LP gas and no attempt should be made to
convert a boiler from natural gas to LP gas.
2) Tank Temperature Control Probe (Hot Water Supply)
3) Remote Temperature Control Probe (Hydronic)
4) Storage Tank T&P Relief Valve
LP gas must be used with great caution. It is highly
explosive and heavier than air. It collects first in the low
areas making its odor difficult to detect at nose level.
5) Manual Gas Shutoff Valve (Supply)
If LP gas is present or even suspected, do not attempt Check the FEATURES AND CONTROLS section for further
to find the cause yourself. Leave the building, leaving information.
7
CONTROL COMPONENTS
flue of the unit is restricted or blocked. The BFS is a normally closed
THE CONTROL SYSTEM
switch that opens when positive pressure is placed on the switch
because of any restriction to the exhaust venting. If the BFS is
activated check and clear any obstructions causing the restriction.
The control system consists of four basic components:
1) Modulation Control Board (MCB); 2) Power Distribution
Board (PDB); 3) Variable Frequency Drive (VFD), see Figure
2; User Interface Module, see Figure 20. The Modulation
Control Board and the Power Distribution Board are located
in the control box and can be accessed by opening the front
door of the unit. The User Interface Module is attached to
the front door panel. Every system will have one Modulation
Control Board (MCB), one Power Distribution Board (PDB),
and one User Interface Module (UIM).
LOW GAS SWITCH
This VF boiler is available with a low gas pressure switch which
meets the CSD-1 code requirements, see Figure 5.
The Low Gas Pressure Switch (LGPS) is normally closed and remains
closed unless the pressure falls below the preset pressure.
The MCB contains dipswitches which are used to configure the
boiler for several different control options, see the Control System
Section.
FIGURE 5.
LOW GAS PRESSURE SWITCH.
FIGURE 2.
WATER FLOW SWITCH
HOT SURFACE IGNITER
The water flow switch is installed at the boiler outlet to
prevent burner operation in the event of inadequate water flow
through the boiler. It is a normally open switch that will close
its contacts when increasing water flow rate is detected. The
water flow switch is factory-set. The contacts will open when
the flow rate drops below the factory setting causing the gas
valve to close which will turn off the gas to the burner, see
Figure 6. Under no circumstances shall the flow switch be
tampered with or bypassed. Doing so may cause damage to
the heat exchanger not covered under the warranty.
The Hot Surface Igniter is a device that ignites the main burner by high
temperature (>1800°F) [982°C], see Figure 3. The igniter is made
of recrystallized silicon carbide, and when 120 VAC is applied to the
igniter, sufficient heat is generated to ignite the main burner. Although
improvements have been made to strengthen the igniter, it is still fragile
and care must be taken in handling the igniter to prevent breakage.
FIGURE 3.
FIGURE 4.
PRESSURE SWITCHES
Thiscontrolsystemhas3pressureswitchesthatarestandard. Blocked
Inlet Pressure Switch (BIS), Blower Prover Switch (BPS) Blocked Flue
Switch (BFS).
FIGURE 6. WATER FLOW SWITCH.
TheBPSonthismodelisanormallyopenswitchthatclosesonincreased
vacuum. Oncetheblowermovesenoughairtocreateavacuumacross
theVenturitheBPSisactivated. Iftheblowerfailsorcannotmovesufficient
air a soft lockout will occur. Inspect the blower for correct operation.
FLAME SENSOR
Each Boiler is equipped with two flame senors coupled together
to detect the presence of the burner flames at high and low fire
conditions. These flame sensors work together as one to sense
the flame. If no flame is sensed, the gas valve(s) will close
automatically. If no flame is sensed on three ignition trials, the boiler
will lock out. In the event of a lockout, depress the SELECT button
on the display board to restart the boiler.
The Blocked Inlet Switch (BIS) will activate is the intake is blocked only
during the heating cycle. The BIS is a normally closed pressure switch
that opens when the air intake is blocked. If the BIS is activated check
and clear the intake of any obstructions.
The blocked flue pressure switch (BFS) activated when the exhaust
8
Temperature Probe allows a boiler to sense the actual water
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.
WATER TEMPERATURE LIMIT CONTROLS
QUAD THERMISTOR PROBE
When connecting up to 4 boilers to a single storage tank
or one primary/secondary hydronic heating system the
optional Quad Thermistor Probe should be used. The Quad
Thermistor Probe is a remote temperature probe with four
temperature sensors embedded in one device. The Quad Thermistor
Probe allows up to 4 boilers to sense system temperature from
same point in the system. Use of the Quad Thermistor Probe
will allow each connected boiler to individually sense actual
water temperature in the storage tank or hydronic heating loop.
The temperatures sensed from each of the four temperature
sensor circuits in a Quad Thermistor Probe are shown as “Tank”
temperature on each boiler’s default Temperatures screen.
The “V(B/W)” models incorporate an outlet water probe consisting
of two limit controls:
1. A Manual Reset High limit control that can be set as high as either
210°F (99°C) or 235°F (113°C), depending on the application.
2. A fixed manual high limit, factory set at 244°F (118°C). If
the manual reset should open due to high temperature, the
gas valves will close and unit will go into lockout. If lockout
occurs, push the SELECTION button on UIM to restart boiler.
ON/OFF SWITCH
NOTE: See the Field Wiring, Remote Temperature Probe
Installation and the Primary System Control sections of this manual
for operating and installation instructions.
The ON/OFF Switch is a single-pole, single-throw rocker switch.
This switch provides 120V from the line source to the boiler.
CIRCULATING PUMP
LOW WATER CUTOFF (OPTIONAL)
HOT WATER SUPPLY BOILER-VW, the circulating pump is
integral to the VW models. This pump has been lubricated
at the factory, and future lubrication should be in accordance
with the motor manufacturer’s instructions provided as a
supplement to this manual.
If boiler is installed above radiation level, a Low Water Cutoff Device
must be installed in boiler outlet at time of installation or, order
pre-installed from the factory. If low water detection is required by
authorities having jurisdiction, a low water cutoff switch should be
installed in the boiler outlet water line. The switch should receive
periodic (every six months) inspection to assure proper operation.
HOT WATER HEATING BOILERS-VB, the circulating pump is NOT
provided on standard models (optional) and must be obtained and
installed in the field.
PRESSURE RELIEF VALVE
NOTE: If a system pump is to be installed on a VB model,
An ASME rated pressure relief valve is furnished with the boiler.
Never operate the boiler if it is not filled with water and a properly
sized pressure relief valve is not installed.
the maximum rating of pump motor must not exceed 1 hp.
TEMPERATURE PROBES
The pressure rating of the relief valve should be equal to or less
than the rated pressure capacity of any component in the system
including the boiler. Should the valve need to be replaced, call
the toll free phone number listed on the back of this manual for
further technical assistance.
INLET / REMOTE
TEMPERATURE
PROBE
OUTLET
TEMPERATURE
PROBE
FIGURE 7. REMOTE PROBE INSTALLATION.
Explosion Hazard
Relief Valve must comply with
ASME code.
Properly sized Relief Valve must
be installed.
Temperature probes are 3/4 inch male NPT threaded immersion
probes, see Figure 7. Temperature probes have embedded
temperature sensors (thermistors). The boiler’s control system
monitors these sensors to determine water temperature at various
points in the system.
Can result in overheating and
excessive tank pressure.
INLET AND OUTLET TEMPERATURE PROBES
All VF boilers have one Inlet and one Outlet Temperature Probe
factory installed in the top of the heat exchanger to monitor the
water temperature entering and leaving the boiler. The Inlet Probe
is a temperature sensor only and has two leads. The Outlet probe
also contains the manual reset high temperature limit switch and
has four leads. The control system displays the Inlet and Outlet
water temperatures sensed from these two probes on the default
Temperatures screen.
Can cause serious injury or death.
Adischarge pipe from the relief valve should terminate at an adequate
floor drain. Do not thread, plug, or cap the end of drain line.
CAUTION
REMOTE TEMPERATURE PROBE
All VF boilers are supplied from the factory with a Remote
Temperature Probe. The supplied Remote Temperature Probe
is used to control system water temperature for a single boiler
in a domestic hot water storage tank or in the return line from a
primary/secondary hydronic heating system. Use of the Remote
Water Damage Hazard
•
Pressure Relief Valve discharge pipe must
terminate at adequate drain.
9
The Discharge Pipe:
• Shall not be smaller in size than the outlet pipe size of the valve, or
have any reducing couplings or other restrictions.
• Shall not be plugged or blocked.
• Shall not be exposed to freezing temperatures.
• Shall be of material listed for hot water distribution.
• Shall be installed so as to allow complete drainage of both the relief
valve and the discharge pipe.
• Must terminate a maximum of six inches above a floor drain or
external to the building. In cold climates, it is recommended that the
discharge pipe be terminated at an adequate drain inside the building.
ThisASME-ratedvalvehasadischargecapacitythatexceedsmaximum
boilerinputratingandapressureratingthatdoesnotexceedmaximum
working pressure shown on boiler rating plate. In addition, a CSA
design-certified and ASME-rated temperature and pressure (T&P)
relief valve must be installed on each and every water storage tank
in hot water supply system. The T&P relief valve must comply with
applicable construction provisions of Standard for Relief Valves for
Hot Water Supply Systems, ANSI Z21.22 or CSA 4.4. T&P relief valve
must be of automatic reset type and not embody a single-use type
fusible plug, cartridge or linkage.
T&P relief valve should have a temperature rating of 210°F (99°C),
a pressure rating not exceeding lowest rated working pressure of
any system component, and a discharge capacity exceeding total
input of water boilers supplying water to storage tank.
• Shall not have any valve or other obstruction between the relief valve
and the drain.
Once the boiler is installed and filled with water and the system
is pressurized, manually test the operation of the pressure relief
valve. See the maintenance section of this manual for instructions.
Locate the T&P relief valve (a) in the top of the tank, or (b) in the side of
the tank on a centerline within the upper 6 inches (152mm) of the top
of the tank, see Figures 14 and 15. The tapping should be threaded in
accordance with the current edition of the Standard for Pipe Threads,
General Purpose (inch), ANSI/ASME B1.20.1. The location of, or in-
tended location for, the T&P relief valve should be readily accessible for
servicing or replacement.
Your local code authority may have other specific safety relief
valve requirements not covered below. If any pressure relief valve
is replaced, the replacement valve must comply with the current
version of the ASME Boiler and Pressure Vessel Code, Section
IV (“HEATING BOILERS”).
VB HOT WATER HEATING BOILERS, are shipped with a 50 psi
(345kPa) pressure relief valve. This relief valve must be installed
in the water outlet as near to the boiler as possible.
VW HOT WATER SUPPLY BOILERS, are shipped with a 125 psi
(860kPa) pressure relief valve that must be installed in the water
outlet as near to the boiler as possible.
GENERAL
REQUIRED ABILITY
INSTALLATION OR SERVICE OF THIS BOILER REQUIRES
ABILITY EQUIVALENT TO THAT OF A LICENSED TRADESMAN
IN THE FIELD INVOLVED. PLUMBING, AIR SUPPLY, VENTING,
GAS SUPPLY, AND ELECTRICAL WORK ARE REQUIRED.
LOCATION
When installing the boiler, consideration must be given to proper
location. The location selected should provide adequate air supply
and be as centralized with the piping system as possible.
If the boiler is installed above radiation level, a Low Water
Cutoff Device must be installed in the boiler outlet at the time of
installation.
PANELS AND COVERS
All panels and covers (e.g. control and junction box covers;
front, side and rear panels of boiler, see Figure 8) MUST be in
place after service and/or before operation of the boiler. This
will ensure that all gas ignition components will be protected
from water.
The VF is a low-pressure boiler (Category IV) to be used as either
hot water supply (domestic/commercial water heating) or hot water
heating (hydronic) application. Category IV boilers operate with a
positive vent pressure and with a vent gas temperature less than
120°F (49°C) above its dew point. Category IV appliances are
often termed “High Efficiency” appliances.
10
UNCONFINED SPACE
In buildings of conventional frame, brick or stone construction,
unconfined spaces may provide adequate air for combustion.
If the unconfined space is within a building of tight construction
(buildings using the following construction: weather stripping,
heavy insulation, caulking, vapor barrier, etc.), air for combustion,
ventilation, and draft hood dilution must be obtained from outdoors
or spaces freely communicating with the outdoors. The installation
instructions for confined spaces in tightly constructed buildings
must be followed to ensure adequate air supply.
UNUSUALLY TIGHT CONSTRUCTION
FIGURE 8.
In unconfined spaces in buildings, infiltration may be adequate to
provide air for combustion, ventilation and dilution of flue gases.
However, in buildings of unusually tight construction (for example,
weather stripping, heavily insulated, caulked, vapor barrier, etc.)
additional air must be provided using the methods described in
the Confined Space section that follows.
CHEMICAL VAPOR CORROSION
Boiler corrosion and component failure can be caused by the
heating and breakdown of airborne chemical vapors. Spray can
propellants, cleaning solvents, refrigerator and air conditioning
refrigerants, swimming pool chemicals, calcium and sodium
chloride (water softener salt), waxes, and process chemicals are
typical compounds which are potentially corrosive. These materials
are corrosive at very low concentration levels with little or no odor
to reveal their presence.
CONFINED SPACE
A Confined Space is one whose volume is less than 50 cubic feet
per 1,000 Btu/hr (4.8 cm per kW) of the total input rating of all
appliances installed in the space.
Products of this sort should not be stored near the boiler. Also, air
which is brought in contact with the boiler should not contain any
of these chemicals. If necessary, uncontaminated air should be
Openings must be installed to provide fresh air for combustion,
ventilation and dilution in confined spaces. The required size for
the openings is dependent on the method used to provide fresh
obtained from remote or outside sources. Failure to observe this air to the confined space and the total Btu/hr input rating of all
appliances installed in the space.
requirement will void the warranty.
DIRECT VENT APPLIANCES
INSTALLTION CLEARANCES
Appliances installed in a Direct Vent configuration that
derive all air for combustion from the outdoor atmosphere
through sealed intake air piping are not factored in the total
appliance input Btu/hr calculations used to determine the
size of openings providing fresh air into confined spaces.
This boiler MUST NOT be installed on carpeted floors. This boiler
is approved for installation on combustible flooring in an alcove with
minimum clearances to combustibles of:
4” (102mm) Rear; 0” (0mm) Top and Sides; 6” (152mm) Vent. 2” (51mm)
clearance is allowable from combustible construction for hot water pipes.
EXHAUST FANS
Sufficientareashouldbeprovidedatthefrontandrearoftheunitforproper
servicing. Service clearances of 24” (610mm) in front, rear, top and sides
are recommended. In a utility room installation, the door opening shall be
wide enough to allow the boiler to enter or to permit the replacement of
another appliance such as a boiler.
Where exhaust fans are installed, additional air should be provided
to replace the exhausted air. When an exhaust fan is installed in
the same space with a water heater, sufficient openings to provide
fresh air must be provided that accommodate the requirements
for all appliances in the room and the exhaust fan. Undersized
openings will cause air to be drawn into the room through the
appliance vent system causing poor combustion. Sooting, serious
damage to the appliance and the risk of fire or explosion may result.
It can also create a risk of asphyxiation.
LEVELING
Each unit should be checked after installation to be certain
that it is level.
If the unit is not level, obtain and insert shims under the feet at the
frame base to correct this condition.
LOUVERS AND GRILLES
The free areas of the fresh air openings in the instructions
that follow do not take in to account the presence of louvers,
grilles or screens in the openings.
AIR REQUIREMENTS
The required size of openings for combustion, ventilation and
dilution air should be based on the “net free area” of each opening.
Where the free area through a design of louver or grille or screen
is known, it should be used in calculating the size of opening
required to provide the free area specified. Where the louver and
grille design and free area are not known, it should be assumed
that wood louvers will have 25% free area and metal louvers and
grilles will have 75% free area. Non motorized louvers and grilles
should be fixed in the open position.
Breathing Hazard - Carbon Monoxide Gas
Install appliance in accordance with
the Instruction Manual and NFPA 54 or
CAN/CSA-B149.1.
To avoid injury, combustion and ventilation
air must be taken from outdoors.
Do not place chemical vapor emitting
products near water heater.
FRESH AIR OPENINGS FOR CONFINED SPACES
The following instructions should be used to calculate the
size, number and placement of openings providing fresh air for
combustion, ventilation and dilution in confined spaces. The
illustrations shown in this section of the manual are a reference
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
11
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.
OUTDOORAIR THROUGH TWO HORIzONTALDUCTS
OUTDOOR AIR THROUGH TWO OPENINGS
FIGURE 9C.
The confined space should be provided with two permanent
horizontal ducts, one commencing within 12 inches (300 mm)
of the top and one commencing within 12 inches (300 mm)
of the bottom of the enclosure. The horizontal ducts should
communicate directly with the outdoors. See Figure 9C.
FIGURE 9A.
Each duct opening should have a minimum free area of 1 square
inch per 2,000 Btu/hr (1100 mm2 per kW) of the aggregate input
rating of all appliances installed in the enclosure.
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. The openings should communicate
directly with the outdoors. See Figure 9A.
When ducts are used, they should be of the same cross sectional
area as the free area of the openings to which they connect. The
minimum dimension of rectangular air ducts should be not less
than 3 inches.
Each opening should have a minimum free area of 1 square
inch per 4,000 Btu/hr (550 mm2 per kW) of the aggregate
input rating of all appliances installed in the enclosure. Each
opening should not be less than 100 square inches (645 cm2).
OUTDOOR AIR THROUGH TWO VERTICAL DUCTS
The illustrations shown in this section of the manual are a reference
for the openings that provide fresh air into confined spaces only.
OUTDOOR AIR THROUGH ONE OPENING
Do not refer to these illustrations for the purpose of vent installation.
See Venting Installation on page 19 for complete venting installation
instructions.
FIGURE 9B.
Alternatively a single permanent opening, commencing within 12
inches (300 mm) of top of enclosure, should be provided. See
Figure 9B. The appliance should have clearances of at least 1
inch (25 mm) from sides and back and 6 inches (150 mm) from
front. The opening should directly communicate with outdoors
or should communicate through a vertical or horizontal duct to
outdoors or spaces that freely communicate with outdoors and
should have a minimum free area of the following:
FIGURE 9D.
The confined space should be provided with two permanent
vertical ducts, one commencing within 12 inches (300 mm) of
the top and one commencing within 12 inches (300 mm) of the
bottom of the enclosure. The vertical ducts should communicate
directly with the outdoors. See Figure 9D.
Each duct opening should have a minimum free area of 1 square
inch per 4,000 Btu/hr (550 mm2 per kW) of the aggregate input
rating of all appliances installed in the enclosure.
1. 1 square inch per 3000 Btu/hr (700 mm2 per kW) of the total
input rating of all appliances located in the enclosure, and
When ducts are used, they should be of same cross sectional area
as free area of openings to which they connect. The minimum
dimension of rectangular air ducts should be not less than 3 inches.
2. Not less than the sum of areas of all vent connectors in
the space.
12
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.
AIR FROM OTHER INDOOR SPACES
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 mm2 per kW) of the aggregate input rating
of all appliances installed in the enclosure. Each opening should
not be less than 100 square inches (645 cm2).
FIGURE 9E.
13
TERMINATION CLEARANCES SIDEWALL POWER VENT
POWER VENT
(using room air for combustion)
EXTERIOR CLEARANCES FOR SIDEWALL VENT TERMINATION
G
V
H
D
A
E
v
L
B
v
B
B
B
V
C
B
D
E
X
I
F
E
D
CLOSED
E
X
I
OPERABL
F
V
M
V
V
X
CLOSED
V
E
X
OPERABL
V
F
B
K
J
A
VENT TERMINAL
AIR SUPPLY INLET
AREA WHERE TERMINAL IS NOT PERMITTED
V
X
Figure 9F.
Vent terminal clearances for “Power Vent” installations. Power Vent configurations use room air for combustion.
1
2
1
2
CANADIAN INSTALLATIONS
US INSTALLATIONS
CANADIAN INSTALLATIONS
US INSTALLATIONS
Clearance to each side
of center line extended
above meter/regulator
assembly
3 feet (91 cm) within a
height 15 feet (4.5 m)
above the meter/regulator
assembly*
Clearance above grade,
veranda, porch, deck or 12 inches (30 cm)
balcony
3 feet (91 cm) within a height 15 feet
(4.5 m) above the meter/
regulator assembly
12 inches (30 cm)
A
B
H
I
6 inches (15 cm) for appliances up to
10,000 Btu/hr (3 kW), 12 inches (30
cm) for appliances between 10,000
Btu/hr (3 kW) and 100,000 Btu/hr (30
4 feet (1.2 m) below
or to side of opening;
1 foot (30 cm) above
Clearance to window
or door that may be
opened
Clearance to service
regulator vent outlet
3 feet (91 cm)
3 feet (91 cm)*
kW), 36 inches (91 cm) for appliances opening
above 100,000 Btu/hr (30 kW)
6 inches (15 cm) for appliances up
to 10,000 Btu/hr (3 kW), 12 inches
(30 cm) for appliances between
10,000 Btu/hr (3 kW) and 100,000
Btu/hr (30kW), 36 inches (91cm)
for appliances above 100,000 Btu/
hr (30 kW)
Clearance to a non
mechanical air supply
inlet into building or
combustion air inlet to
any other appliance
4 feet (1.2 m) below or to
side of opening; 1 foot
(30 cm) above opening.
Clearance to
permanently closed
window
12 inches (30 cm)*
12 inches (30 cm)*
C
J
Vertical clearance to
ventilated soffit located
above the terminal
within a horizontal
distance of 2 feet (61
cm) from the center line
of the terminal
3 feet (91 cm) above if
within
10 feet (3 m) horizontally
Clearance to a
mechanical air supply
inlet
12 inches (30 cm)*
12 inches (30 cm)*
12 inches (30 cm)*
12 inches (30 cm)*
6 feet (1.83 m)
7 feet (2.13 m)†
D
E
K
Clearance above paved
sidewalk or paved
driveway located on
public property
Clearance to
unventilated soffit
7 feet (2.13 m)
L
Clearance under
veranda, porch, deck, or 12 inches (30 cm) ‡
balcony
Clearance to outside
corner
2 feet (60 cm)*
8 ft. (2.44 m)*
2 feet (60 cm)*
8 ft. (2.44 m)*
12 inches (30 cm) ‡
F
M
Clearance to inside
corner
G
1 In accordance with the current CSA B149.1, Natural Gas and Propane Installation Code.
2 In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code.
† A vent should not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings.
‡ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.
* Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer’s installation instructions.
14
TERMINATION CLEARANCES SIDEWALL DIRECT VENT
DIRECT VENT
(using outdoor air for combustion)
EXTERIOR CLEARANCES FOR SIDEWALL VENT TERMINATION
G
V
H
D
A
E
v
L
B
v
B
B
B
V
C
B
D
E
X
I
F
E
D
CLOSED
E
X
I
OPERABL
F
V
M
V
V
X
CLOSED
V
E
X
OPERABL
V
F
B
K
J
A
VENT TERMINAL
AIR SUPPLY INLET
AREA WHERE TERMINAL IS NOT PERMITTED
V
X
Figure 9G.
Vent terminal clearances for “Direct Vent” installations. Direct Vent configurations use outdoor air for combustion.
1
2
1
2
CANADIAN INSTALLATIONS
US INSTALLATIONS
CANADIAN INSTALLATIONS
US INSTALLATIONS
Clearance to each side
of center line extended
above meter/regulator
assembly
Clearance above grade,
veranda, porch, deck or 12 inches (30 cm)
balcony
3 feet (91 cm) within a height 15
feet (4.5 m) above the meter/
regulator assembly
3 feet (91 cm) within a height
15 feet (4.5 m) above the
meter/regulator assembly*
12 inches (30 cm)
A
B
H
I
6 inches (15 cm)
for appliances up to
10,000 Btu/hr (3 kW),
9 inches (23 cm) for
appliances between
10,000 Btu/hr (3 kW)
and 50,000 Btu/hr (15
kW), 12 inches (30 cm)
for appliances above
50,000 Btu/hr (15 kW)
6 inches (15 cm) for appliances
up to 10,000 Btu/hr (3 kW), 12
inches (30 cm) for appliances
between 10,000 Btu/hr (3 kW)
and 100,000 Btu/hr (30 kW), 36
inches (91 cm) for appliances
above 100,000 Btu/hr (30 kW)
Clearance to window or
door that may be opened
Clearance to service
regulator vent outlet
3 feet (91 cm)
3 feet (91 cm)*
6 inches (15 cm) for
6 inches (15 cm) for appliances up
to 10,000 Btu/hr (3 kW), 12 inches
(30 cm) for appliances between
10,000 Btu/hr (3 kW) and 100,000
appliances up to 10,000
Btu/hr (3 kW), 9 inches (23
cm) for appliances between
10,000 Btu/hr (3 kW) and
50,000 Btu/hr (15 kW), 12
inches (30 cm) for appliances
above 50,000 Btu/hr (15 kW)
Clearance to a non
mechanical air supply
inlet into building or
Clearance to
permanently closed
window
6 inches (15 cm)*
6 inches (15 cm)*
C
J
combustion air inlet to Btu/hr (30 kW), 36 inches (91 cm)
any other appliance
for appliances above 100,000 Btu/
hr (30 kW)
Vertical clearance to
ventilated soffit located
above the terminal within
a horizontal distance of
2 feet (61 cm) from the
center line of the terminal
Clearance to a
mechanical air supply
inlet
3 feet (91 cm) above if within
10 feet (3 m) horizontally
12 inches (30 cm)*
12 inches (30 cm)*
12 inches (30 cm)*
12 inches (30 cm)*
6 feet (1.83 m)
D
E
K
Clearance above
Clearance to unventilated
soffit
paved sidewalk or
paved driveway located
on public property
7 feet (2.13 m)†
7 feet (2.13 m)†*
L
Clearance under
veranda, porch, deck,
or balcony
Clearance to outside
corner
2 feet (60 cm)*
8 ft. (2.44 m)*
2 feet (60 cm)*
8 ft. (2.44 m)*
12 inches (30 cm) ‡
12 inches (30 cm) ‡*
F
M
Clearance to inside
corner
G
1 In accordance with the current CSA B149.1, Natural Gas and Propane Installation Code.
2 In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code.
† A vent should not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings.
‡ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.
* Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer’s installation instructions.
15
VENTING
2. Through-the-Wall Termination (TWT) - horizontal vent
termination directly through an outside wall, see Figure 11A.
3. Horizontal Direct Vent - using TWT to exhaust flue products
and PVC piping to bring combustion 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.
GENERALEXHAUSTVENTINSTALLATIONPROCEDURE
Prior to beginning the installation of the vent system, determine and
obtain all parts required for the installation. IF THIS INSTALLATION IS
ADIRECTVENTINSTALLATIONADIRECTVENTKITISREQUIRED.
REFER TO THE PARTS LIST FOR KIT NUMBER.
Proper operation of the boiler and venting system is dependent
upon use of all specified parts and installation techniques; both
safety and proper performance of the system may suffer if
instructions are not followed.
CONNECTING VENT TO BOILER
Referring to Figure 10., combustion gases are vented using AL29-
4C material. Transition from the horizontal outlet to a vertical vent
is achieved through the use of a boot-tee and drain cover or other
engineering approved arrangement. A support bracket should be
located at the transition point.
VENT SIZING, INSTALLATION AND TERMINATION SHALL
BE IN ACCORDANCE WITH THIS INSTALLATION MANUAL.
ALL ELECTRICAL POWER AND GAS MUST BE TURNED OFF
PRIOR TO ANY INSTALLATION OF THE VENTING SYSTEM. The drain connection is necessary for the removal of condensate
which may form in the stack. A rubber hose 3/8” ID and 10 feet
long is provided for directing the condensate to a suitable drain.
SPECIAL INSTALLATION CONSIDERATIONS
1. Attach the Boot Tee Drain Cover to the appropriate leg of the
Boot-Tee, see Figure 10.
2. Atrap loop must be formed into the drain tube simply by looping
the tube to a minimum 3 inch (76mm) diameter and secure the
loop with a cable tie, see Figure 10.
This boiler is a category IV appliance that can be vented using room
air for intake combustion air, or direct vented so that all intake air for
combustion comes from the outside through a sealed pipe. When
installing this boiler as direct vent, special vent kits are required.
3. Prior to final assembly the trap loop must be “primed” by pouring
a small quantity of water into the drain hose.
In cold climates any water vapor remaining in the flue gases will condense
into a cloud of vapor at the point where the vent system exits the building.
Specialconsiderationisrecommended,beforelocatingtheventtermination
near walkways, windows and building entrances.
4. Connect the Boot-Tee and Drain Tee assembly (or engineering
approved equivalent) to the boiler vent connector, see Figure 10.
5. Attach the hose to the drain fitting and run the hose to a sanitary
sewer drain maintaining the proper trap loop and following all
local, state and federal codes and regulations for draining of
acidic effluent (condensate).
Direct venting into dead 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.
To prevent the recirculation of flue gases, maintain as much
distance as possible between the combustion air intake and the
exhaust vent terminal. Due to large volumes of flue gases, multiple
boiler applications also require additional distance between the
intake and exhaust terminals.
VENTING SYSTEM USING AL 29-4C®
This boiler may be installed in four separate orientations depending
on the requirements of the building and the appliance. The installer
must decide which method is most appropriate for each installation.
These orientations are:
1. Vertical Termination - vertical vent termination through un-
enclosed or enclosed areas with roof penetration, see Figure 11.
Figure 10.
16
4. Maintain a minimum of 6 feet (2.0m) separation between
VENTING SUPPORTS
the air intake and the exhaust terminals.
Care must be taken in the installation of the venting system that
adequate support is maintained throughout the installation process.
When extending more than 10 feet (3.0m) vertically, vertical support
kits are required once every 10 feet (3.0m) of vertical run. Vertical
support is also required immediately after any transition (elbow,
tee, etc.) to vertical of over 10 feet (3.0m) of run and after any
offset in the vertical run.
HORIzONTAL INSTALLTION REQUIREMENTS
1. The vent system must terminate with a AL 29-4C® Vent
Through-the-Wall Termination (TWT). Plan the terminal
location based on the dimensions shown in Figure 9. Do
not locate the terminal within 8 feet (2.5m) of an inside
corner of a building or adjacent to outside walls, shrubs or
other such objects that may cause adverse wind conditions
in the immediate area.
The support brackets (supplied in the Vertical Support Kit) are to be
securely fastened to a solid vertical member of the building using the
appropriate fasteners; i.e., wood screws for wood framing, machine or
tapping screws for structural steel or masonry anchors for solid masonry.
The bracket should be located so that it will not interfere with any joints of
the venting system. The bottom most support bracket should be located
directly above the first transition from horizontal to vertical, see Figure
10. Refer to Figures 12, 12A, 12B and 12C.
2. The TWT shall be located not less than 12 inches (305mm)
above grade or, in geographical areas where snow
accumulates, no less than 12 inches (305mm) above the
anticipated snow line. Ensure that the TWT is protected
against blockage which may occur during ice buildup or
snowstorms.
If a means of support for the brackets are not available and
horizontal vent sections are present, install hanger straps
(made from non-combustible material) as close to the points of
transition as possible. If the horizontal portions of the vent and/or
vent connector are longer than 6 feet (2.0m), then install hanger
straps every 6 feet (2.0m) to support the connector.
The TWT shall terminate at least 3 feet (1.0m) above
any forced air inlet within 10 feet (3.0m), except when
the forced air inlet is the combustion air intake of a
direct vent appliance. The TWT shall terminate at least
4 feet (1.2m) below, 4 feet (1.2m) horizontally from or
1 foot (305mm) above any door, window or gravity air
inlet into any building as provided in the current edition
of the NATIONAL FUEL GAS CODE ANSI Z223.1, see
Figure 9.
DO NOT rivet or screw the straps to the conduit or otherwise
puncture the conduit wall. Instead, wrap an extra loop of strap
around the conduit to hold it in position, or attach the strap to
the center screw of the double wall AL 29-4C® vent coupling, if
applicable.
In addition, a minimum clearance of 4 feet (1.2m) hori-
zontally from, and in NO CASE ABOVE OR BELOW,
unless the 4 feet (1.2m) of horizontal distance is main-
tained from electric meters, gas meters, regulators and
relief equipment.
VERTICAL INSTALLATION REQUIREMENTS
1. The vent system must terminate at least 3 feet (1.0m)
and no more than 6 feet (2.0m) above the roof line and
no closer than 10 feet (3.0m) from any wall or vertical
structure. If the exhaust vent terminal is within 10 feet
(3.0m) of a wall or parapet, it must extend a minimum of
2 feet (610mm) above the wall or parapet, see Figures
11 and 12A.
3. This horizontal exhaust vent system must pitch upward toward
the termination at 1/4 inch per foot (21mm per meter).
4. The TWT is designed such that the building is protected
from degradation by flue gas and condensate. However,
if additional protection is desired, install against the wall
a non-corrosive metal sheet under the TWT.
2. For direct vent installations, the total distance of the vent system
from the boiler vent connector to the vertical vent termination shall
not exceed 70 equivalent feet (21.3m). A maximum of three 90°
elbows can be used. Minimum vertical vent is 7 equivalent feet
(2.1m) for direct vent installations. Standard minimum vertical vent
length is 7 feet (2.1m), plus Boot-Tee. See Figures 11, 12A, 12B, and
12C for differences between standard and direct vent installations.
5. Due to the normal formation of water vapor in the combus-
tion process, horizontal terminations must not be located
over areas of pedestrian or vehicular traffic, (i.e., public
walkways or over areas where condensate could create
a nuisance or hazard). This is especially true in colder
climates where ice buildup is likely to occur. A.O. Smith
Corporation will not be held liable for any personal injury
or property damage due to any dislodging of ice.
3. An AL 29-C® Vent Vertical Vent Terminal must be used at
the termination.
17
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.
FIGURE 11A. HORIzONTAL THROUGH THE WALL TERMINATION (TWT).
18
1. The Air-Intake System (AIS) must terminate with the venting
equipment provided with the boiler, Refer to the parts list for
required direct vent parts.
DIRECT VENT INSTALLATION REQUIREMENTS
Follow the guidelines in the “HORIZONTAL INSTALLATION
REQUIREMENTS” section for the exhausting of flue
products.
2. The AIT shall not be located less than 3 feet (1.0m) below
any exhaust vent within 10 feet (3.0m), see “HORIZONTAL
INSTALLATION REQUIREMENTS” section.
IMPORTANT
3. The total horizontal distance of the AIS from the boiler’s Blower
Adapter to the outside of the “AIT” shall not be greater than 70
“equivalent” feet (21.3m) of vent pipe nor less than 3 feet (1.0m),
excluding elbows.Amaximum of 3 elbows, equivalent to 10 feet
(3.0m) each of pipe may be used.
The labels in the Direct Vent Kit must be affixed to the boiler
in locations specified by the instruction sheet provided in
the kit. The following are requirements for the Air-Intake
Terminal (AIT):
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 back-up
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.
19
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. To prevent the
recirculation of flue gases, maintain as much distance
as possible between the combustion air intake and the
exhaust vent terminal.
FIGURE 12. DIRECT VENT HORIzONTAL.
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. To prevent the recirculation
of flue gases, maintain as much distance as
possible between the combustion air intake
and the exhaust vent terminal.
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 12A. DIRECT VENT VERTICAL.
20
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)
OF A WALL OR A PARAPET, IT MIUST EXTEND A MINIMUM
OF 2’ (0.6m) ABOVE THE WALL OR PARAPET.
EQUIVALENT FEET (27.4m)
•
•
ON SIDEWALL VENT INSTALLATION, REFER
TO FIGURE 9F FOR SPACING SPECIFICATIONS
FOR EXHAUST AND AIR INTAKE PIPE INSTALLATIONS
(CLEARANCES, SUPPORT, ETC.) REFER TO FIGURES
12 AND 12A.
FIGURE 12B. DIRECT VENT, VERTICAL VENT TERMINATION WITH HORIzONTAL INTAKE.
VERTICAL AIR INTAKE MUST BE
12” (305mm) ABOVE ANTICIPATED
SNOW LEVEL.
PVC PIPE 70 EQUIVALENT FEET (27.4m)
70 EQUIVALENT FEET (27.4m)
OF VENTING (MAX.) AL 29-4C®
NOTES:
•
IF THE EXHAUST VENT TERMINAL IS WITHIN 10’ (3.0m)
OF A WALL OR A PARAPET, IT MIUST EXTEND A MINIMUM
OF 2’ (0.6m) ABOVE THE WALL OR PARAPET.
•
•
ON SIDEWALL VENT INSTALLATION, REFER
TO FIGURE 9G FOR SPACING SPECIFICATIONS
FOR EXHAUST AND AIR INTAKE PIPE INSTALLATIONS
(CLEARANCES, SUPPORT, ETC.) REFER TO FIGURES
12 AND 12A.
FIGURE 12C. DIRECT VENT USING TWT WITH VERTICAL INTAKE.
21
SYSTEM INSTALLATION
related to the total water volume of the system. Refer
to “Systems and Equipment” volume of the ASHRAE
GENERAL
handbook.
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 prevent a downdraft entering the boiler
or freezing air from contacting the system. Failure to do so
may cause the water in the system to freeze with resulting
damage to the system. DAMAGE DUE TO FREEZING IS
NOT COVERED BY THE WARRANTY.
An air separator as shown in the piping diagrams is recom-
mended especially for modern commercial hydronic systems.
3. VENT VALVES
It is recommended that automatic, loose key or screw-
driver type vent valves be installed at each convector
or radiator.
Good practice requires that all heavy piping, etc., be supported.
4. SYSTEM HEADERS
Figure 13 shows a typical primary, secondary piping method.
This is the preferred piping method for most copper fin tube
boilers. Other piping methods, however, may provide good
system operation. A prime concern when designing heating
systems is the maintenance of proper flow through the unit
during boiler operation. The secondary pump should be sized
per the recommended flow rate of the boiler, see Dimension
and Capacity Data in this manual.
Split systems with individual supply and return lines from
the boiler room should normally have this piping connected
to supply and return manifold headers near the boiler. To
achieve good water distribution with maximum pressure
drop for several circuits, manifolds should be larger than
system mains.
The circuits should be spaced on the heater at a minimum
of 3” (76mm) center to center. Install a balancing cock in
each return line.
A system bypass should be installed, as shown in Figure
13, to prevent boiler circulation starvation when the system
zones call for reduced flow.
Manifold headers are recommended for split systems
with or without zone valves and also those installations
with zone circulators. If the system is to be split at
remote points, good practice requires special attention
be given to main pipe sizing to allow balancing of water
flow.
This bypass may also be used with multiple boilers manifolded
for reverse-return flow. This system bypass would be installed
from boiler outlet to suction side of pump.
HOT WATER HEATING (HYDRONIC) EQUIPMENT
5. COOLING PIPING
The following is a brief description of the equipment required
for the installations noted in this manual. All installations
must comply with local code.
When the boiler is used in conjunction with a refrigeration
system it must be installed so that the chilled medium is
piped in parallel with the boiler. Appropriate flow control
valves, manual or motorized, must be provided to prevent
the chilled medium from entering the boiler.
1. WATER SUPPLY LINE
These boilers can be used ONLY in a forced circulation
hot water heating system. Since most forced circulation
systems will be of the closed type, install the water supply
line as shown on piping diagram, see Figure 13.
Water temperature in the heating system must be reduced
to less than 100°F (38°C) before cooling system is started,
or damage to the chiller unit may occur.
Fast filling of large pipe, old radiator installations and
pressure purging of series loop systems (where high
pressures are not available) requires bypassing of the
pressure reducing valve.
If the boiler is connected to chilled water piping or its
heating coils are exposed to refrigerated air, the boiler
piping system must be equipped with flow valves or other
automatic means to prevent gravity circulation through the
boiler during the cooling cycle.
Generally, pressure purging is not possible with a well
pump system. High point air venting is essential.
Primary/secondary pumping of both the chiller(s) and
the boiler(s) is an excellent winter-summer change-over
method, because cooling flow rates are so much more
than heating flow rates. In this way each system (heating
or cooling) is circulated independently.
If the system is of the open type, a pressure reducing
valve will not be required as the water supply to the
system will be controlled by a manually operated valve.
An overhead surge tank is required. A minimum pressure
of 15 psi (100kPa) must be maintained on the boiler at
all times to ensure avoidance of potential damage to the
boiler which may not be covered by the warranty.
6. CIRCULATING PUMP
FOR HOT WATER HEATING BOILERS - VB MODELS, the
circulating pump is NOT provided and must be field-installed.
2. EXPANSION TANK
NOTE: If a system pump is to be installed on a VB
model, the maximum rating of the pump motor must
not exceed 1 hp.
If the system is of the closed type, install an expansion
tank as shown in Figure 13. The sizing of the expansion
tank for a closed system is very important and is directly
22
7. SYSTEM CONTROLLER
HOT WATER SUPPLY BOILER SYSTEM - GENERAL
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
temperature thermostat(s). Multiple boiler installations are
more effective when the boilers are sequenced in and out of
operation by some form of main water temperature controller.
With one or two boilers, individual control settings at
progressive temperature may be used. For more than
two boilers, electronic sequencing controlling is
recommended. Individual controls, or the separate stages
of a step controller, should start the boiler loop circulator
and fire the boiler. Some large installations may require the
firing of more than one boiler per stage.
This section provides detailed installation diagrams for a
typical method of application for the unit.
Piping diagrams will serve to provide the installer with
a reference for the materials and methods of piping
necessary for installation. It is essential that all water
piping be installed and connected as shown on the
diagrams. Check the diagrams to be used thoroughly
before starting installation to avoid possible errors and to
minimize time and material cost.
It is essential that all water piping be installed and
connected as shown on the diagrams. Check the diagrams
to be used thoroughly before starting installation to avoid
possible errors and to minimize the time and material cost.
The system or primary circulator may or may not be
controlled by the boiler sequencer. When this pump is
operated through the first switch of any type of step
controller, care should be taken to determine if a motor
starter is needed due to insufficient switch capacity.
HARD WATER CONDITIONS
Multiple boiler installations are especially adapted to the
use of outdoor reset for main water temperatures. This
feature is not mandatory, but offers smooth, efficient
operation of a modern system.
Where hard water conditions exist, water softening or the
threshold type of water treatment is recommended. This
will protect the dishwashers, coffee urns, water heaters,
water piping and other equipment. When water softening
or water treatment is not practical, a comparatively easy
method of periodic lime removal from the unit may be
employed.
Normal use of flow control valves is required to prevent
cross circulation of zones as with any multiple pump system.
Large systems with multiple boilers should include main
water temperature controls (with or without outdoor
reset) to sequence the boiler on and off, in relation to
the load on the system.
SHUTOFF VALVES SHOULD BE INSTALLED FOR
SERVICING BOILER, HOWEVER, LOCAL CODES SHALL
GOVERN THEIR USAGE.
24VAC System Controller (Optional) - VB models require
a field supplied 24VAC operating control to be installed in
the system such as: loop thermostat, indoor/outdoor reset
control, sequencing panel, or energy management system.
The connection for such devices is located in the junction
box at the rear of the unit. A 24VAC thermostat/aquastat can
only be used as an “On/Off” switch for the unit. The actual
controlling of the phasing will be through either the inlet or
remote probe. To use a 24VAC system controller, dipswitch
“4” on the MCB must be switched to the “on” position, see
REMOTE PROBE INSTALLATION.
THERMAL EXPANSION (CLOSED SYSTEM)
As water is heated, it expands (thermal expansion). In
a closed system the volume of water will grow when it is
heated. As the volume of water grows there will be a
corresponding increase in water pressure due to thermal
expansion. Thermal expansion can cause premature tank
failure (leakage). This type of failure is not covered under
the limited warranty. Thermal expansion can also cause
intermittent Temperature-Pressure Relief Valve operation:
water discharged from the valve due to excessive pressure
build up. This condition is not covered under the limited
warranty. The Temperature-Pressure Relief Valve is not
intended for the constant relief of thermal expansion.
INTERNAL CONTAMINANTS
The hydronic system must be internally cleaned and flushed
after a new or replacement boiler has been installed, to
remove contaminants that may have accumulated during
installation. This is extremely important when a replacement
boiler is installed into an existing system where Stop Leak
or other boiler additives have been used.
A properly sized thermal expansion tank must be installed on
all closed systems to control the harmful effects of thermal
expansion. Contact a local plumbing service agency to have
a thermal expansion tank installed.
Failure to clean and flush the system can produce acid
concentrations that become corrosive, and leads to heat
exchanger failure.
REMOTE PROBE INSTALLATION PROCEDURE
A remote probe is supplied with each hot water supply
boiler (VW models). To connect the remote probe to the
boiler, remove the cover from the junction box at the rear
of the unit. Connect the probe wire pigtails, see Figure 7.
Check the field connection diagram located on this cover
of the junction box to assure proper wiring.
All hot water heating systems should be completely flushed
with a grease removing solution to assure trouble-free opera-
tion. Pipe joint compounds, soldering paste, grease on tubing
and pipe all tend to contaminate a system
Failure to flush contaminants from a system can cause solids
to form on the inside of boiler exchangers, create excessive
blockage of water circulation, deterioration of the pumps seal
and impellers.
Once the remote probe has been connected to the boiler, it
must be designated as the controlling probe for the system.
23
This is accomplished by changing two dipswitch settings on the
MCB. First, dipswitch “4” must be set to the “ON” position to
When local codes require a main manual shut-off valve
outside the boiler jacket, a suitable main manual shut-off valve
designate the remote probe as the controlling probe. Second, must be installed in a location complying with those codes.
dipswitch “1” must be set to the “OFF” position to limit the
Before attaching the gas line be sure that all gas pipe is clean on
maximum remote probe temperature for VW applications. Also,
the inside.
make sure dipswitch “1” is set to the “OFF” position, which sets
To trap any dirt or foreign material in the gas supply line, a
drip leg (sediment trap) must be incorporated in the piping. The
drip leg must be readily accessible and not subject to freezing
conditions. Install in accordance with recommendations of serving
gas supplier. Refer to the current edition of the national fuel gas
code, ANSI Z223.1 or CAN/CSA – B149.1, and current addenda.
the outlet temperature for VW applications. Failure to do this
will void the warranty. If the remote probe is not designated
as the controlling probe, the unit will be controlled by the inlet
probe and will not use the desired tank temperature as its base.
Refer to Connection Diagram, Figure 17, in order to connect
the remote probe to the boiler, see Tables 9, 10, 13 and 14
for Dipswitch positions.
Size of gas supply piping may be larger than heater connection on
installations where a significant run of piping is required.
GAS CONNECTIONS
To prevent damage, care must be taken not to apply too much
torque when attaching gas supply pipe to boiler gas inlet.
Fittings and unions in the gas line must be of the metal to metal type.
Apply joint compounds (pipe dope) sparingly and only to the male
threads of pipe joints. Do not apply compound to the first two threads.
Use compounds resistant to the action of liquefied petroleum gases.
GAS SUPPLY LINE SIzING
The gas piping installation must be capable of supplying the
maximum probable gas demand without excessive pressure loss.
Depending on local practices, the ALLOWABLE PRESSURE
LOSS between the gas meter, or service regulator and each
appliance is generally 0.3 or 0.5 inches of water column (0.075
or 0.124kPa).
For single boiler installation, refer to Table 5 for appropriate pipe
length for the appliance maximum rate.
Make sure the gas on which the boiler is to operate is the
same as that specified on the rating plate. Do not install
the boiler if equipped for a different type of gas. Consult
your gas supplier.
For multiple boilers refer to Table 6 for natural gas and Table 7 for
propane. Maximum pressure drop is 0.5 for these charts.
Reference tables are from ANSI Z223.1 National Fuel Gas Code or
CAN/CSA-B149.1-00 (and current addenda):
This boiler is not intended to operate at gas supply pressure
other than shown on the rating plate. A lock-up or positive
shut-off type regulator must be installed in the gas supply
line. Exposure to higher gas supply pressure may cause
damage to gas valves which can result in fire or explosion.
If overpressure has occurred such as through improper
testing of gas lines or emergency malfunction of the supply
system, the gas valves must be checked for safe operation.
Make sure that the outside vents on the supply regulators
and the safety vent valves are protected against blockage.
These are parts of the gas supply system, not the boiler.
Vent blockage may occur during ice build-up or snowstorms.
Natural gas is 1000 BTU/ft^3 @ 0.6 specific gravity
Propane gas is 2500 BTU/ft^3 @ 1.5 specific gravity
< pipe length longer than 200 feet consult applicable codes
No additional allowance is necessary for an ordinary number of
fittings. Where it is necessary to use more than the average number
of fittings (i.e., elbows, tees and valves in gas supply line) use a pipe
larger than specified to compensate for increased pressure drop.
TABLE 5.
SINGLE UNIT INSTALLATION, SUGGESTED GAS PIPE SIzING.
MAXIMUM EQUIVALENT PIPE LENGTH (IN FEET).
The boiler must be isolated from the gas supply piping
system by closing its main manual gas shut-off valve during
any pressure testing of the gas supply piping system at
test pressures equal to or less than 1/2 psig.
0.3 in w.c. drop
Nom. Pipe
BTU input
500,000
750,000
1,000,000
1”
1.25”
1.5”
2”
Nat Prop Nat Prop Nat Prop Nat Prop
10
25
10
40
10
10
90
40
20
80
40
20
200
90
50
200
125
70
Disconnect the boiler and its main manual gas shut-off valve
from the gas supply piping during any pressure testing of the
gas supply system over 1/2 psig. The gas supply line must be
capped when not connected to the boiler.
<
175
0.5 in w.c. drop
1.25” 1.5”
Nat Prop Nat Prop Nat Prop Nat Prop
Nom. Pipe
BTU input
500,000
750,000
1,000,000
1”
2”
It is important to guard against gas valve fouling from
contaminants in the gas ways. Such fouling may cause
improper operation, fire or explosion. If copper supply
lines are used they must be approved for gas service.
10
40
10
10
60
30
10
150
70
150
70
200
150
90
<
200
125
40
30
<
24
25
26
27
There are five (5) electrical connections that must be made
for the unit to operate correctly:
WIRING
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.
*** Enable/disable can also be used with a 24 volt thermostat.
Do not use tank probe when using thermostat.
Verify proper operation after servicing. Strict adherence to the
wiring diagrams is required to prevent constant pump operation
when the system controller is satisfied. Otherwise the warranty is
void as stipulated in the limited warranty in this installation manual.
These connections shall be made at the rear of
the unit where a junction box is provided.
AN
If any of the original wire, as supplied with the appliance, must be
replaced, it must be replaced with type 105°C wire or its equivalent.
ELECTRICAL GROUND IS REQUIRED TO REDUCE
THE RISK OF ELECTRIC SHOCK OR POSSIBLE
ELECTROCUTION. A GROUND SCREW IS PROVIDED
IN THIS JUNCTION BOX.
NOTE: Tank probes are not provided on VB models,
it is required that a system/operating temperature
controller (field supplied) be installed to regulate
loop or system temperatures. Two yellow wires are
provided in the rear junction box for this connection.
Do not operate this boiler without system or
operating control.
When operating the boiler with the tank probe the enable/disable
must be wired together.
Refer to the Connection Diagram, see Figure 17, and to
the Schematic Diagram, see Figure 18.
Figure 16.
28
SUGGESTED PIPE SIzING TABLES
29
WIRING DIAGRAM
VB/VW-500, 750 & 1000 SCHEMATIC DIAGRAM
FIGURE 18. - SCHEMATIC DIAGRAM
32
OPERATION
IMPORTANT
Only qualified personnel shall perform the initial firing of the boiler.
At this time the user should not hesitate to ask the service agent
any questions regarding the operation and maintenance of the unit.
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.
However the user should not attempt repairs, but should contact
a service technician or gas supplier.
GENERAL
Never operate the boiler without first making sure the boiler and
system are filled with water, in addition:
For hot water supply installations:
• Make sure a temperature and pressure relief valve is installed at
the boiler and, if used, the storage tank. Also check for leaks.
For heating boiler installations:
• Make sure that the boiler and system have been purged of air
and checked for leaks.
Also be sure to check the gas piping for leaks before beginning the
initial firing of the boiler.
INLET GAS PRESSURE
The inlet gas pressure is measured by removing the 1/8” NPT Plug
located on the main gas manifold which is upstream of the unit’s gas
valve, and insert a 1/8” NPT hose barb fitting to be connected to a
manometerorpressuregauge. Oncepressurehasbeencheckedand/
oradjusted, replacetheplugandcheckforleaks.Themaximumvalue
specified in the table must not be exceeded. The minimum values,
shown in Table 1, must be maintained under both load and no load
conditions (static and firing conditions). The combination gas valves
supplied with the boiler are for low pressure service. If upstream
pressure exceeds 14.0” W.C., an intermediate gas pressure
regulator of the lockup type must be installed.
FILLING AND PURGING OF HEATING BOILER
INSTALLATION
1. Fast fill system through bypass until pressure approaches
desired system pressure. Close bypass valve and permit
pressure to be established by the pressure reducing valve.
2. Vent all high points in system to purge system of air.
Provisions should be made to permit manual venting of radiators
or convectors.
FILLING HOT WATER SUPPLY BOILER
INSTALLATION
1. Close the system’s drain valve by turning handle clockwise.
2. Open a nearby hot water faucet to permit the air to escape.
3. Fully open the cold water inlet pipe valve allowing the boiler
and piping to be filled.
4. Close the hot water faucet as water starts to flow.
5. The boiler is ready to be operated.
PURGING GAS LINE
Gas line purging is required with new piping or systems in which
air has entered.
FIGURE 19. GAS TRAIN ASSEMBLY.
33
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.
TABLE 8. Risk of Scalds.
Time to Produce 2nd & 3rd Degree
Water Temperature
Burns on Adult Skin
Over 170°F (77°C)
160°F (71°C)
Nearly instantaneous
About 1/2 second
150°F (66°C)
About 1-1/2 seconds
Less than 5 seconds
About 30 seconds
More than 5 minutes
140°F (60°C)
WATER TEMPERATURE REGULATION
130°F (54°C)
120°F (49°C) or less
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)differentialbetweentheboiler’sinletandoutlet(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 and the outlet valves at the rear
of the boiler, see Figures 14 and 15, are required; wait at least
one minute between adjustments for the temperature to stabilize.
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 oth-
ers. 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 should 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. Fol-
low the manufacturer’s instructions for installation of the valves.
Before changing the thermostat setting on the hot water system
controller, see Table 8.
1) If necessary, throttle down (close) the water outlet gate/ball
valve until the desired outlet water temperature (120°F [49°C]
minimum) is reached. Wait one minute.
2) Note the outlet and inlet temperature indicator readings.
a) If the inlet water temperature is less than 120°F (49°C),
open, in small increments, the bypass (balancing) valve
until the minimum 120°F (49°C) inlet water temperature
or 20°F (11°C) differential, whichever has the higher inlet
temperature, is attained.
b) If the inlet water temperature is greater than 120°F (49°C)
and the 20°F (11°C) differential is not present, close the
bypass valve until the 20°F (11°C) differential is attained.
NOTE: It may be necessary to make further adjustments on
the outlet and bypass valves until the desired inlet and outlet
water temperatures are reached.
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 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.
MANIFOLD PRESSURE CONNECTIONS
Take the manifold pressure, refer to Table 1, by removing
the pipe plug and inserting a suitable 1/8” NPT hose barb for
connection to the manometer/pressure gauge. Upon completion
of measurements and adjustments, remove the hose barb
and replace the pipe plug. Check for gas leaks and insure all
connections are gas tight, see Figure 19..
34
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. The status of all dipswitches can be observed on the system status screen on the UIM.
TABLE 9. - MCB/FCB Dipswitches:
Dipswitch Function
Switch Position
Hot Water Boilers
Hydronic Heating Boiler
Off = VW
Switch 1: Selection of the type of boiler application:
Switch 2: Trials for ignition:
On = VB
On = 3
Off = 1
Switch 3: IRI Gas Valve Not Available:
Switch 4: Controlling Probe:
On = Tank (Remote)
On = Yes
On = Yes
On = Yes
On
Off = Inlet
Off = No
Off = No
Off = No
Switch 5: Powered Venter:
Switch 6: Low Water Cut Off: (LWCO)
Switch 7: Low Gas Pressure
Switch 8: Modulation:
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.
Example of Dipswitch configuration:
VB model, 1ignition trial, not used, tank / remote probe, no power vent, No LWCO,
no low gas pressure, modulation, not used, not used.
MCB - Three position Dipswitch:
This dipswitch is similar to the MCB dipswitches described above, 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.
TABLE 10.
Dipswitch Function:
Dipswitch Position
Switch 1: Spare:
Switch 2: Hi Gas pressure switch:
Switch 3: Number of Blower Speeds:
On = Yes
Off =
Off =
No
On = 1 speed,
2 speed
Example of Dipswitch configuration:
No High Gas, 1 blower speed.
35
LIGHTING & OPERATION INSTRUCTIONS FOR MODELS VB/VW 500, 750 AND 1000:
36
TABLE 12. - LOW FIRE SETTING
ADJUSTMENT
NATURAL
PROPANE
6.5 - 7.5% CO2
7.5 - 8.5% CO2
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. This will expose the offset adjustment screw.
Using a TORX® T40 or a 5mm hex wrench, carefully adjust
the low fire gas setting to achieve the CO2 level prescribed
in above reference table. Note: The rotation of the Low
Fire adjustment is opposite of the High Fire as follows:
Clockwise rotation increases gas flow, counterclockwise
rotation decreases gas flow.
There must be sufficient load to operate the boiler at high fire to
Adjustments to the offset pressure regulators should not exceed 1/4
perform the following adjustments. Start the boiler and observe turn at a time before allowing the readings to respond and stabilize.
proper operating parameters for the system.
After proper low fire offset adjustment is made, reinstall the slotted
cap on the regulator.
Required Tools:
TORX® T40 or 5mm hex wrench
3mm or 7/64in hex wrench
Combustion analyzer
Following all gas valve adjustments, check for proper light-off and
verify correct fuel/air mix and combustion quality throughout the
entire firing range (from lowest to highest fan speed).
CONTROL SYSTEM
The VF 500, 750, and 1000 boilers are equipped with a Honeywell
combined gas/air control and gas safety shut off control valves. The
valve functions in parallel with the variable speed combustion blower to
supply the correct gas air ratio for optimum performance and efficiency.
The combustion blower speed is controlled automatically and determines
the amount of negative pressure experienced by the gas safety shut off/
control valves. The gas/air regulator adjusts gas flow to maintain the proper
pressure at the outlet nozzle of the associated valve.
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), see Figure 2.
Power Distribution Board (PDB), see Figure 2.
User Interface Module (UIM), see Figure 20.
SETTING OF THE TEST MODE
On UIM go to main menu, scroll down to user settings and press select.
Scroll down to MOD mode, press select. Use the up and down keys
to select options: MIN (MINIMUM FIRING RATE). MAX (MAXIMUM
FIRING RATE). MOD (FOR AUTOMATIC MODULATION MODE).
Press select for the desired option. For checking the combustion setup
on MIN or MAX the boiler will remain in this state for ten minutes before
defaulting to the MOD (modulation) mode.
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-character LCD
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.
TABLE 11. - HIGH FIRE SETTING
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.
NATURAL GAS
PROPANE
8.5 - 9.0% CO2
9.5 - 10.5% CO2
Set boiler to the “Test Mode High,” as described above, to
achieve maximum firing rate of the boiler. Check combustion
readings using a combustion analyzer. If combustion readings
are not in accordance with the chart above adjust as follows:
remove the flat, round, blue plastic cap from the cover.
Using a 3mm (7/64”) hex wrench, turn the adjustment screw
counterclockwise to increase or clockwise to decrease gas flow
and achieve the desired CO2 level. See Table referenced above
for correct settings. There will be a slight time delay between
the adjustment and the response of the CO2 measuring
instrument. Adjust the settings in small increments and allow
the combustion readings to stabilize before readjusting. When
desired adjustments are complete, reinstall the blue plastic cap
on the cover. Combustion samples shall be taken within two
feet of the boiler. IMPROPER ADJUSTMENT CAN CAUSE
INCOMPLETE COMBUSTION RESULTING IN DEATH.
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
sequences and safety features associated with a gas ignition
control system. The system continuously performs various
diagnostic tests to verify proper appliance and control
operation. Should an unsafe condition occur, the control
will shut down the burner and display a red service light as
well as indicate the cause of the error on the display. The
operating programs for the system are stored in permanent
memory inside the microcontrollers. User-selectable
operating parameters and a history of detected faults are
stored in rewritable memory in the microcontrollers. A loss
of power does not affect either of the memories.
37
FLAME SENSOR:
INPUTS TO MCB
Flame (MCB - required): Returns a signal to the microprocessor
if flame is detected on the burner. If the flame rod is missing or
shorted, the flame will not be detected.
TEMPERATURE SENSORS:
Temperature probes (MCB - outlet and either inlet or tank are
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
located inside the outlet probe. It is a normally closed switch that
opens if the probe is exposed to a temperature higher than the trip
point. Once tripped, the control system needs to be manually reset.
RELAY CONTACT OUTPUT:
Alarm (MCB - 24VAC - optional): Provides electrical power to
operate an external alarm. This can be an audio device (i.e.,
Sonalert), a visual device (lamp), or any other device that will
operate with the voltage and current level provided.
Thermostat input (MCB - optional): This input is set up to work with
an externally connected thermostat that provides a contact closure. If
this input is 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
systemshouldbesethigherthanthetemperaturethatthethermostatis
controlling.This will allow the thermostat to control the boiler. When the
thermostat closes, a call for heat will be generated until the thermostat
determines that the required temperature has been reached.
Pump (MCB - 120VAC - required on systems that do not have
an external pump): Provides electrical power to directly operate a
pump or the coil of an externally connected contactor.
Blower (MCB - 120VAC - required): Variable speed blowers utilize
the high blower output only.
Igniter (MCB - 120VAC - required): Provides power to operate
the HSI igniters.
Gas Valve (MCB - 24VAC - required): Provides power to activate
the gas valve. The gas valve cannot be activated when the MRHL
contacts are open.
AIRPRESSURESENSORS(OPENCONDITIONINDICATESFAULT):
Blocked Inlet (MCB - required) Normally closed switch that
activates if the air inlet is blocked 3/4 or more during operation.
Low Water Cut Off (MCB - 24VAC - optional): Directly connected to
the 24VAC line to provide power to operate an external LWCO device.
Blocked Flue (MCB - required): Normally closed switch that opens
if the flue becomes blocked during operation.
MCB AND PDB INDICATOR LAMPS AND FUSES
Blower Prover (MCB - required): Normally open switch that closes
when the air pressure produced by the blower is above the set point.
A green LED is mounted on the PDB to indicate when line voltage
is applied (the PDB also contains a yellow and red LED, and a test/
run jumper that are used during installation to verify proper power
connections). A red LED on the MCB is used to indicate when the
24VAC input fuse has blown.
GASPRESSURESENSORS(OPENCONDITIONINDICATESFAULT):
Low Gas (MCB - required): Normally open switch that closes when
the gas pressure rises above the trip level. This input is enabled/
disabled by a dip switch on the MCB
Yellow LEDs are located near the microcontrollers on the MCB.
These LEDs are “heartbeat indicators,” and blink approximately
twice per second to indicate that the microcontrollers are
running.
Hi Gas (MCB - required): Normally closed switch that opens if the
gas pressure exceeds a set value. This input is enabled/disabled
by a dip switch on the MCB.
WATER LEVEL SENSOR (OPEN CONDITION INDICATES FAULT):
MCB JUMPERS
Low Water Cut Off (MCB - optional): Normally open switch that
closes when water reaches preset level. This input is enabled/
disabled by a dip switch on the MCB.
The MCB has two jumpers. JP1 on the MCB is used to terminate
the external communications line. It is normally left off and installed
when the external cable is very long.
WATER FLOW SENSOR:
IGNITERS
Flow (MCB - required): Normally open switch that closes when
flow exceeds a set value.
The EMC modulation system operates with Silicon Carbide Igniters
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. The status of all dipswitches can be observed on the system status screen on the UIM.
TABLE 13. - MCB/FCB Dipswitches:
Dipswitch Function
Switch Position
Hot Water Boilers
Hydronic Heating Boiler
Off = VB
Switch 1: Selection of the type of boiler application:
Switch 2: Trials for ignition:
On = VW
On = 3
Off = 1
Switch 3: IRI Gas Valve Not Available:
Switch 4: Controlling Probe:
On = Tank (Remote)
On = Yes
On = Yes
On = Yes
On
Off = Inlet
Off = No
Off = No
Off = No
Switch 5: Powered Venter:
Switch 6: Low Water Cut Off: (LWCO)
Switch 7: Low Gas Pressure
Switch 8: Modulation:
38
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.
Example of Dipswitch configuration:
VB model, 1ignition trial, not used, tank / remote probe, no power vent, No LWCO,
no low gas pressure, modulation, not used, not used.
MCB - Three position Dipswitch:
This dipswitch is similar to the MCB dipswitches described above, 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.
TABLE 14.
Dipswitch Function:
Dipswitch Position
Switch 1: Spare:
Switch 2: Hi Gas pressure switch:
Switch 3: Number of Blower Speeds:
On = Yes
Off =
Off =
No
On = 1 speed,
2 speed
Example of Dipswitch configuration:
No High Gas, 1 blower speed..
6. After a few seconds the blower is turned on for 30-second
pre-purge period of combustion chamber.
OPERATING SEQUENCE
1. The EMC modulation controller has four modes of operation:
Initialization, Standby, Running/Modulation, and Service. The
internal MCB micros control these modes through a sequence
of steps (or States) which are further described in the “UIM
Operating Procedures” section.
7. The igniter is turned on.
8. After the igniter has reached a minimum of 2.8 amps, the gas
valve is energized to allow gas flow to burner.
9. After an additional one second, the system checks the status of
the flame through the flame sensor. If the flame is not verified
within 4 seconds, the gas valve is immediately shut off followed
by 15-second inter-purge period, then the system returns to
step 7, if the “Trial for Ignition” dipswitch is set for three (3) tries.
If the dipswitch is set for one (1) trial, the system will declare
an error and boiler will require resetting the control.
2. When power is applied to the system, it enters the initialization
mode and the following automatic functions are performed:
•
•
A. O. Smith opening screen is displayed.
The system goes through a calibration indicated by the
green running LED blinking and then staying on; next the
red service LED and yellow standby LEDs come on, next
the service and runnings LEDs blink ON and OFF.
10. The boiler will remain running until the set point is satisfied.
Once satisfied, the blower will continue for 15-second post
purge period.
•
•
•
•
Stored values are recalled from memory.
Configuration dipswitches are read.
Pending faults are recalled
11. Once set point has have been satisfied, the boiler pump will
continue to run for the programmed post-circulate cycle.
12. The control now enters the idle state as displayed by the
“Standby” LED. The control will continue to monitor heat
demand and state of other system devices. Upon a drop of
water temperature below the set parameters, the control will
return to step 5 and repeat the entire operating cycle. Note:
Any fault detection, during standby or running modes, will halt
the heating sequence and shift the system to the service mode
where the detected fault will be displayed.
Micros on all boards start running (indicated by a flashing
Yellow LED near each micro)
•
Input sensors are read
3. After initialization is complete (approximately 10 seconds)
the system turns the green LED off and goes to the standby
mode (yellow “Standby” LED on), unless a previously stored
fault has been recalled, which will send the system into the
service model (red “Service” LED on). In standby mode the
display shows the temperature screen and in fault mode the
current error screen is displayed.
NOTE: In standby and running modes the system constantly
monitors the signals and the internal operation for faults. Any
detected fault will halt the heating sequence and shift the system
to the service mode, where the detected fault will be displayed.
4. The system then compares the temperature read from the
controlling probe (inlet or tank) to the setpoint temperature. If
the temperature is less than the operating setpoint minus the
differential temperature and the thermostat input is closed then
a call for heat is established and the system shifts to the run
mode (green “Running” LED turns on).
TEMPERATURE SETPOINTS (SYSTEM CONTROL ALGORITHM)
The boiler has a hysteresis type control, which means that it will
begin heating the water when the temperature sensed by the
control probe (inlet or tank) falls below the operating setpoint minus
the differential setpoint. It will stop heating the water when the
temperature rises to the operating setpoint.
5. The heating sequence begins by applying power to the pump.
39
after the Igniter is turned on until the igniter is turned off and an
off condition at all other times.
UIM OPERATING PROCEDURES
•
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.
Control Status Screen:
Displays the status that the MCB micros are in. The MCB has
5 possible states and the FCB have 9. The normal MCB states
sequence is to move from Idle to Pre-Circulate when a call for
heat is initiated. Once heat has been satisfied or the Thermostat
is opened, the sequence moves to Post-Circulate and then back to
Idle. If a fault occurs at any time, the process jumps out of sequence
and goes directly to the appropriate Hard or Soft Fault state.
Description of MCB control states:
•
Idle:
FIGURE 20. UIM, USER INTERFACE MODULE
The yellow “Standby” LED is turned on and the system waits
for a heat request (determined by the Thermostat or controlling
probe inputs). All outputs are off in this state except that if the
Post-Circulate time is set to continuous, the pump will be on.
When the heat request is received, the system moves to the
Pre-Circulate state.
The UIM receives commands from the user and displays operational
information to the user via an LCD (liquid crystal display) up to eleven
LED’s, and five touch switches. The LCD provides information to
the user by the use of 10 menu-activated screens. Within each of
the screens, helpful information can be displayed by pressing the
“Help” button. The LED’s visually inform the user about the mode
the system is in. The touch switches allow the user to control the
operation of the system. The operation of these parts is described
in the following section:
•
•
•
Pre-Circulate:
The yellow LED is turned off and the green “Running” LED is
turned on. The green LED will remain on for all other states
except the fault states. 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.
UIM Screens:
On all screens a double vertical bar appears on the right side of
the display each time a key is touched to indicate that a key has
been activated. On several screens an indicator “>” appears on
the left side of the display to indicate the active line. The “Up/
Down” keys are used to move the indicator to the desired line and
the “Select” key is pressed to select the line. Also, on most of the
screens, up/down arrows appear on the right side of the screen
to indicate that there is additional lines either above or below the
displayed four lines.
Heat Stage
The system will command the FCB micros to start their heat
sequence. will be activated in order based on an algorithm that
determines how much heat is needed. The system will remain in
this state until the heat request is satisfied, the Tstat is opened,
or a fault occurs.
Soft Fault State: (See “Fault Description” section for list of soft
and Auto Reset faults.)
•
Menu Screen:
Displayed when the user presses the “Menu” key. This screen
is the selection point for the other 9 screens.
The pump remains on for the selected post-circulate time to
cycle the hot water out of the boiler. The FCB is commanded
to shut down and theAlarm output is turned on. The green LED
turns off and the red “Service” turns on. The MCB remains in
this state until one of the following occurs:
•
Temperature Screen:
Displays the sensed temperatures of the Outlet, Inlet, and
Tank probes. Also displayed is the calculated Delta T (Outlet
minus Inlet) for the system. Shorted (“Short”) and disconnected
(“----”) probes are also displayed.
• One hour passes (automatic restart after one hour)
• If Communications error system will automatically
restart if communications re-establishes.
•
System Status Screen:
• If user presses Select key while current error screen is
displayed (Hard reset).
This screen is used to view the status of switch inputs and output
states. An asterisk (*) is displayed next to the label when the
status is “True” (the description is fulfilled). For example, if
water is flowing, or detected by the flow sensor, then an “*” will
appear in front of the Flow label (i.e. *Flow). Another example
would be the ECO switch. If the outlet temperature is too high
the display will show: *ECO.
• If high-limit error - the outlet temperature drops below the
high limit trip point minus the high limit differential. (outlet
water temperature drops to safe level). The fault is logged
in the error history when the fault state is exited.
• Hard Fault State: (See “Fault Description” section for list of
soft and Auto Reset faults.) The pump remains on for the
selected post-circulate time to cycle the hot water out of the
boiler. The FCB is commanded to shut down and theAlarm
output is turned on. The green LED turns off and the red
“Service” turns on and off (flashes). The only way to exit
this state is for the user to press the Select key while the
current error screen is displayed. The fault is logged in the
error history when the fault state is exited.
The System monitors the inputs of these times:
•
MRHL, Blocked Inlet, Blocked Flue, Low Gas, Hi Limit, and Hi
Gas - at all times for a fault condition.
•
•
Tstat - at all times for open/closed conditions.
Flow-for an on condition when the pump is on (no check for off
state)
•
•
Blower Prover - when the Blower is on.
While the MCB is in the Heating mode the FCB moves from Idle, to
Pre-Purge, to Heat Igniter, to Check for Flame, and then to Heating.
Igniter Current - for an on condition approximately 18 seconds
40
The process waits in this state until the call for heat is satisfied, the
thermostat input is opened, or a fault occurs. When heat is satisfied,
the sequence continues to Post-Purge and then back to Idle. If
three tries for ignition has been selected on the MCB dipswitch and
flame is not detected at the appropriate time, then the sequence
moves to the Inter-Purge state for 15 seconds and the FCB heat
sequence is repeated. If flame is still not detected after the third try
the process declares a fault, jumps out of sequence and goes to
the error state. Other types of faults detected at any time will also
cause a jump to the error state.
•
Cold Purge State
Cold purge occurs when the MCB micro commands the
blower to go on before lighting to clear the unit of residual
gases. This state normally lasts approximately 32 seconds
but on a special situation can last up to 5 minutes. If
on the first call for heat after power up, blower prover
switch is open, this state will take up to 5 minutes before
declaring an error.
The MCB will wait the normal cold purge time (normally 32
seconds) before checking for activation of all active blower
prover. If blower prover is active at this time the MCB cancels
the cold purge request. After the first cold purge has been done
a flag is set to prevent further activation of the shutter adjust 5
minute delay. Any further requests for cold purge will last the
normal cold purge time. The FCB will go into fault mode if the
blower prover does not activate after 15 seconds. This time
allows the blower relay to activate, the blower to come up to
speed, and the response from the blower prover to be filtered.
Description of FCB control states:
•
Idle State:
When any error is declared during idle state-The system will
remain in this state until the MCB request a heating cycle, or a
cold purge.
•
•
Pre-Purge State:
The blower is turned on. After 10 to 34 seconds (34 seconds
for cold purging) the system switches to the Heat Igniter State.
•
•
User Settings Screen:
Heat Igniter State:
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.
The following setpoints can be changed:
The sequence of operation is as follows: “The igniter relay is
energized and the heat up period begins. After 18-20 seconds,
if the igniter has reached a minimum of 2.8 amps, the gas valve
safety circuit is then activated. If in this amount of time, the igniter
fails to reach a minimum amp draw of 2.8 amps, the unit will
re-cycle up to 3 times before locking out on igniter hardware
failure. If the igniter does reach the minimum required amp draw
of 2.8 amps, the gas valve circuit is energized, and the system
advances to Flame Check status.
Operating Setpoint:
This setpoint sets the base temperature for the control algorithm.
OPERATINGSETPOINTADJUSTMENTPROCEDURE
•
Check for Flame State:
The system has a standard programmable Operating Setpoint
range of 70°F (21°C) to 190°F (88°C) for a VW and of 70°F
(21°C) to 220°F (104°C) for a VB for either a Remote or inlet
probe depending on selection. The user can easily change
the Operating Setpoint at any time by using the following
procedure. When any configuration or setpoint is changed
(and the Select key touched), the new value is IMMEDIATELY
saved to non-volatile memory. The factory default setting is
120°F (49°C).
The gas valve is turned on. After 1.5 seconds, the system
checks that the gas valve relay is on. If it is not, the ignition
trial is considered to have failed and the system advances to
the Inter-Purge state, if any ignition trials remain, otherwise an
error is declared.
The flame sensor is checked. If flame is detected, the igniter
is turned off. The state machine then advances to the Heating
State. If after 5 seconds, the flame is still not sensed then the
ignition trial is considered to have failed. The state machine
advances to Inter-Purge if any ignition trials remain, otherwise
an error is declared.
1. Press the MENU key.
2. Scroll the “>” with the DOWN key next to the USER SETTING
SCREEN.
•
Heating State:
3. Press the SELECT key.
The system remains in this state until the call for heat is
cancelled or a fault occurs. The system returns to the Idle state
if the call for heat is cancelled, or satisfied and to the appropriate
fault state if a fault occur.
4. Scroll the “>” with the DOWN key until it is pointing to
OPERATING SETPOINT.
5. Press the SELECT key.
•
•
Inter-Purge State:
6. Use the UP or DOWN key to select the value you wish to enter.
7. Press the SELECT key to accept and store the new value.
The gas valve and the igniter are turned off. The blower is on.
After approximately 15 seconds the system goes back to the
Heating Igniter State.
•
High Limit:
The outlet temperature probe contains both an ECO switch
and a thermistor for temperature measurement. The sensed
outlet temperature is used for the automatically resettable High
Limit setpoint. If the sensed outlet temperature exceeds the
High Limit setpoint, a “soft lockout” condition will occur and
the burner will be shut off. This fault condition is automatically
cleared when the temperature drops below the high limit
setpoint minus the high limit differential.
Post-Purge State
The gas valve and the igniter are turned off. If this stage
does not have a blower the system returns to the idle
state. If it does have a blower then the blower is left
on. After approximately 25 seconds, the system returns
to the Idle state.
•
Error State
AUTO HIGH LIMIT SETPOINT ADJUSTMENT PROCEDURE/
OUTLET TEMPERATURE PROBE
The gas valve and the igniter are turned off. The FCB micro tells
the MCB micro which error has occurred. The system waits in
this state until the MCB sends a command to clear the error,
and the system returns to the idle state.
The High Limit setpoint has a range of 90°F (32°C) to 210°F (99°C)
for a VW and a range of 90° (32°C) to 235°F (113°C) for a VB.
41
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)
The software revision level of the MCB.
Current Error Screen:
2. Scroll the “>” with the DOWN key next to USER SETTING SCREEN.
3. Press the SELECT key.
•
4. Scroll the “>” with the DOWN key until it is pointing to HIGH
LIMIT SETPOINT.
Displays the last error that the system has detected plus a time
stamp of when the error occurred. (The time stamp is based
on the elapsed hours value at the time the error occurred. It
is displayed in hours and minutes. This error remain displayed
as long as it is still valid. When cleared it is moved to the Error
History Screen. The system will automatically jump to this screen
when an error is detected. It will also go to this screen upon
power-up if an error was still valid when power was turned off.
5. Press the SELECT KEY.
6. Use the UP and DOWN key to select the value you wish to
enter.
7. Press the SELECT key to accept and store the new value.
•
High Limit Differential:
The outlet temperature must be below the automatic High Limit
setpoint minus the High Limit Differential setpoint before a call
for heat can be generated.
NOTE: Errors are cleared from this screen by pressing
the “select” key.
•
•
Error History Screen:
HIGHLIMITDIFFERENTIALSETPOINTADJUSTMENT
PROCEDURE
This screen displays a list of the last 9 errors (with time
stamps) that have occurred. The last error to occur
is displayed first. If a new error occurs this screen is
presented to display the error.
The High Limit Differential Setpoint has a range of 1°F to 50°F for
all models. Use the following procedure to change the High Limit
Differential Setpoint:
Reload Defaults Screen:
1. Press the MENU key.
From this screen the user can restore the factory default
values for screen adjustable configurations by pressing
the Select key. The values restored are as follows:
2. Scroll the “>” with the down key next to USER SETTING
SCREEN.
3. Press the SELECT key.
VW Models
4. Scroll the “>” with the DOWN key until it is pointing to HIGH
Oper Setpnt (Operating Setpoint) - 145° F (63° C)
Hi Limit (High Limit Setpoint) = 210° F (99° C)
Hi Limit Dif (High Limit Differential) = 20° F (11° C)
VB Models
LIMIT DIFFERENTIAL SETPOINT.
5. Press the SELECT key.
6. Use the UP or DOWN key to select the value you wish to enter.
7. Press the SELECT key to accept and store the new value.
Oper Setpnt (Operating Setpoint) = 190° F (88° C)
Hi Limit (High Limit Setpoint) = 230° F (110° C)
Hi Limit Dif (High Limit Differential) = 20° F (11° C)
Both Models
•
Operating Differential Setpoints:
Each of the two stages has an independent Operating
Differential setpoint.
•
•
Temperature Units:
Temperature can be displayed in either °F or °C units.
Post Circulate Delay Time:
Tempert Units (Temperature Units) = F
Post Cir Secs (Post Circulation pump delay = 45 seconds
Network Address (Network Address) = (none)
The time circulation pump will stay on after the burner
is turned off. The time in seconds is adjustable with the
following values: 45, 90, 180 or continuous. If the continuous
value is selected the pump will remain on at all times and
the post circulate state time will be set at 45 seconds.
UIM Touch Switches
Below the LCD display are five touch switches or keys, that the
operator uses to operate the system.
•
•
Menu Key:
•
Network Address:
Pressing this key activates the menu screen where the other
screens can be accessed.
This is a unique number assigned to this boiler to differentiate
it from other boilers or water heater on the same A. O.
Smith proprietary network. A valid Network Address can be
any number from 1 to 31. It is set by default to zero, which
is an invalid address. The boiler will not communicate until
it is changed to a valid and unique number. This prevents
two units from trying to respond to the same request from
the PC or supervisory network device.
Select Key:
This key performs several functions. Screens can be selected
from the menu screen by pressing this key when the “>” appears
next to the screen desired.
On the User Settings screen items that appear next to a “>”
symbol can be selected with this key. If a setpoint configuration
item is selected, the “>” will then flash slowly to indicate that
the item has been selected. The Up and Down keys are then
used to change its value.
•
•
Configuration Settings Screen:
Displays the status of the dipswitches installed on all
boards as described earlier.
Log & System Info Screen:
From the Current Error Screen this key is used to reset the
system from an error:
Displays the following information:
42
•
Up and Down Keys:
has been detected and the system has stopped running.
It is on continuously for soft faults and flashes for hard
faults. The Yellow LED indicates that the boiler is in a
ready mode waiting for a call for heat command. When
on continuously the Green LED indicates that the system
is in the heating mode. If it is flashing it indicates that the
UIM is in the initialization mode and the touch switches are
being calibrated.
These keys are used to move upwards and downwards in
screens to reach a desired item and to change setpoints
and user settings. They have an auto increment/decrement
feature for some of the configurations and values. When
you first press one of the keys and value changes by 1
count, then wait 1/2 second and changes slowly until the
key is released or if held for 3 or more seconds it will
change the value quickly.
The VF® boiler has a display on the UIM which is a scaled display
indicating the current firing rate of the boiler (25% to 100%).
•
Help Key:
Pressing the Help key from any screen displays helpful
information about that screen. From the menu screen,
general help information is displayed as to how to use the user
interface. To return to the previous screen press the Help or
Select keys, or press Menu key to go to the menu screen. If a
small down arrow appears in the lower right hand corner then
there is off screen content below what is displayed. Press the
down arrow to scroll down to this information. After scrolling
down an up arrow will appear in the upper right hand corner
to indicate off screen content above what is displayed.
Fault Messages and Troubleshooting Guide
The EMC 5000 modulation system does excessive self-
diagnostics and displays detected faults on the UIM display
in an easy to read manner. There are approximately 80
different faults that can be detected. Some of the faults are
caused by internal problems and some by external causes.
The faults create different types of system lockouts (shut
down). Hard lockouts are serious problems that require the
user to manually restart the system. Soft lockouts can be reset
by the user or after 60 minutes the system will automatically
clear the error and restart. Auto Reset lockouts will monitor
the cause of the fault and it the fault clears itself the system
resets itself. The following table shows the fault messages
and some possible troubleshooting hints:
UIM LED’s
The three LED’s to the right of the LCD indicate the status
of the overall system. The red LED indicates that a fault
43
TROUBLESHOOTING IGNITION SYSTEM
Fault Messages and Lockout Status (* = stage number: 1, 2, 3, or 4)
FAULT DISPLAYED
“Display Fail”
DESCRIPTION
RED LED
LOCKOUT
Auto Reset
Communications with UIM interrupted
Continuous
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. Fail Stg.*”
“Low AC Voltage”
“Low 24VAC”
Communications with FCB interrupted
Same as above. Also try swapping FCB and UIM communications cables.
Line voltage less than 90 vac
Check incoming power line for loss of voltage. May also be caused by a power line brown-out (momentary loss of voltage)
Voltage from transformer less than 18 vac Continuous Auto Reset
Check transformer output. Should be over 24vac. May be caused by excessive current drain or a faulty transformer
Indicates a brown out reset occurred - - - - None
Continuous
Auto Reset
Continuous
Auto Reset
“Brown Out Reset”
Caused by a momentary dip in voltage on the MCB +5vdc power bus. Contact factory. (Not considered a serious problem
if it only occurs on very rare occasions.)
“Timeout Reset”
Indicates a watchdog reset occurred
- - - -
None
Caused when the micro executes the software in an improper way. Contact factory. (Not considered a serious problem if it
only occurs on very rare occasions.)
“FCB Comm Timeout”
FCB did not receive command from MCB
Continuous
SOFT
Caused when communications between the MCB and the FCB are interrupted. May occur when a surge of power on a
nearby device (i.e. arc welder) creates an EMI burst. Not a serious problem if it occurs rarely.
“No Flow”
Water is not flowing
Continuous
SOFT
Caused by the flow switch being open when it should be closed. Check water lines, pump, flow switch contacts, wiring.
“Blower Prov Stg*
“Blocked Flue”
Blower pressure is too low it they should have been closed.
Check blower, switch contact, wiring, and for air leaks.
Flue is Blocked
Continuous
SOFT
Continuous
SOFT
Caused by the blocked flue switch contacts being open when they should have been closed. Check for flue blockage, switch
contacts, wiring.
“Blocked Inlet”
“High Limit”
“MRHL”
Air Inlet is blocked
Check inlet terminal, venturi screen and burner tube for debris. If inlet is clear check blocked inlet flue switch for continuity.
Inspect hose to switch to ensure it is connected and not cracked or spilt.
Outlet temp. exceeded high limit setpoint
Caused when the temperature of the outlet probe exceeds the high limit setpoint. This is an internal “software” limit switch and
not an actual device. Check that the over temperature is not being caused by improper setup or operation of the boiler.
Outlet temp is too high
Continuous
Auto Reset
Flashing
HARD
Caused when the MRHL (a thermostat) contacts in the Outlet probe are open when they should be closed. Fault may be due
to high outlet temperature, bad switch contacts in the probe, or disconnected wiring. Note: The MRHL can be checked by
disconnecting the outlet probe from the MCB and reading the resistance across the two active pins on the connector at the
end of the probe cable. The value should be approximately 0 ohms when the temperature of the probe is less than 220°F.
“Low Water”
Water level is too low
Flashing
HARD
Caused by the Low Water Cut Out device not closing its feedback switch contacts when it should. Check water line, switch
contacts, wiring, LWCO.
“Low Gas”
Gas pressure is too low
Caused by the Low Gas switch being open when it should be closed. Check gas line, switch contacts, wiring.
Power vent not running Flashing HARD
Flashing
HARD
“Powered Accessory”
Caused by the Powered Vent device not closing its feedback switch contacts when it should. Could also be caused by a
problem with the relay output on the MCB. Check output to powered vent, switch contacts, wiring.
“High Gas Stg*”
Gas pressure too high
Caused by the High Gas switch being open when it should be closed. Check gas line, switch contacts, wiring.
Inlet probe shorted or open Flashing HARD
Flashing
HARD
“Inlet Probe”
Caused when the thermistor in the probe or the wiring to the probe is shorted or disconnected. Check the probe. Note: The
thermistor and wiring can be checked by disconnecting the probe from the MCB and reading the resistance across the two
active pins on the connector at the end of the probe cable. The value should be approximately 10K ohms (value will change
slightly with changes in temperature).
“Outlet Probe:”
“Tank Probe”
“Igniter Stg*”
Outlet probe shorted or open
Flashing
HARD
Caused when the thermistor in the probe or the wiring is shorted or disconnected. Check the probe. Note: the thermistor and
wiring can be checked by disconnecting the probe from the MCB and reading the resistance across the two active pins on
the connector at the end of the probe cable. The value should be approximately 10K ohms (value will change slightly with
changes in temperature).
Tank (Remote) probe shorted or open
Flashing
HARD
Caused when the thermistor in the probe or the wiring is shorted or disconnected. Check the probe. Note: the thermistor and
wiring can be checked by disconnecting the probe from the MCB and reading the resistance across the two active pins on
the connector at the end of the probe cable. The value should be approximately 10K ohms| (value will change slightly with
changes in temperature).
Igniter current is too low
Flashing
HARD
Caused by a low current draw problem with the igniter. This may occur if the igniter is old, damaged, or disconnected and
no longer draws the proper level of current. This condition will affect the ability of the igniterto get hot enough to fire the gas
properly. Check the igniter and its associated wiring.
“Igniter Pwr Stg*”
Improper power applied to the igniter circuit
Flashing
HARD
Caused by improper line power being applied to the igniter circuitry. Check line connections. Paying particular attention to
the earth ground connection. Also check that line voltage does not exceed 132 VAC RMS.
“Igniter Hdwr Stg*”
Hardware problems with igniter circuit
Flashing
HARD
44
Problem: Gas OK, no burner start up (both shutoff valves are
open, fan turns)
TROUBLESHOOTING GAS VALVE
There is not enough gas to accommodate a start up. Turn throttle
screw ½ turn counterclockwise and try to start again with more
gas.
Problem: Non-linear CO2 curve on adjusted boiler (deviation
more than 3-6%)
1. Possible blockage at the air inlet that prevents uniform,
constant air flow.
2. The gas inlet pressure is too low at full load.
Problem: Boiler makes noise at high CO2 level
Premix-boilers may have a loud whistle noise problem
at high CO2 levels. This can sometimes be alleviated by
decreasing the CO2 level.
Problem: Unstable CO2 level at minimum load
The minimum load (low fire) is too low. The pressure difference
on the pressure regulator at minimum load must be at least
0.2 in wc (50 Pa). If the pressure difference does not meet
this requirement, it may be necessary to adjust low fire
setting, see Setting Test Mode.
Problem: Strong oscillations at burner start
It is normal for a small oscillation to occur in the first second
of the burner start. If the oscillation is very strong or lasts very
long, decrease the resistance of the chimney by using a shorter
tube with a larger diameter. An additional solution is to change
the start up power of the burner.
The pressure difference on the regulator can be measured between the
venturi and the feedback tube. It is necessary to unscrew the pressure
tap on the venturi for this measurement, and to close it afterwards.
Problem: Nominal power of the mixing unit is unattainable
Possible causes for this issue are:
With 17% of the reference load and a CO2 level of 8.7%, it should
be possible to reach this minimum pressure difference. If
the CO2 level is higher, the minimum power also has to be
proportionally higher than 17%.
1. the boiler and burner head pressure drop is too large;
2. fan not turning at correct speed.
3. sensing tube is clogged or broken.
Problem: After some time, the pressure regulation of
the valve fails
Problem: No gas, no burner start up
Dirt in the valve finer than 0.013” (0.34mm) can prevent the correct
function of the servo pressure regulator. Replace the valve and add
a gas filter in front of the new valve.
Check whether both coils of the two shutoff valves are energized
and whether both shutoff valves are opening (you should hear a
double “click” in the valve). Also check the gas inlet pressure.
PREVENTATIVE MAINTENANCE
This is a pre-mix burner system. The flame is not supposed to be
directly on the burner. The flame should be just above the burner
deck approximately 1/8” and blue in color, see Figure 21.
MAIN BURNER
Check main burner every three months for proper flame
characteristics. The main burner should display the following
characteristics:
• Provide complete combustion of gas.
• Cause rapid ignition and carry over of flame across entire burner.
• Give reasonably quiet operation during initial ignition, operation
and extinction.
• Cause no excessive lifting of flame from burner ports, see
Figure 21.
If the preceding burner characteristics are not evident, check for
accumulation of lint or other foreign material that restricts or blocks
the air openings to the burner or boiler. To check burners:
1. Shut off all gas and electricity to unit. Allow unit to cool.
2. Remove main burners from unit.
FIGURE 21. BURNER FLAMES
3. Check that burner ports are free of foreign matter.
4. Clean burner with vacuum cleaner. DO NOT distort burner ports.
5. Reinstall burners in unit. Ensure that all the screws on the burner
flange are tightened securely so that the gasket will provide a good
seal.
Visually check flame characteristics through the view port
located on the top head of the boiler. Figure 21 shows the
normal flame condition.
6. Also check for good flow of combustion and ventilating air to
the unit.
These boilers are designed to give many years of efficient and
satisfactory service when properly operated and maintained.
To assure continued good performance, the following
recommendations are made.
After placing the boiler in operation, check the ignition system safety
shut-off devices for proper operation. To accomplish this with the
main burner operating, close the valve on the manifold. Within
four seconds the main burners should extinguish. If this does not
occur immediately, discontinue gas supply by closing main manual
shut-off and call a qualified service agent to correct the situation. If
the burners extinguish, then light boiler in accordance with lighting
and operating instructions.
The area around the unit should be kept clean and free from
lint and debris. Sweeping the floor around the boiler should
be done carefully. This will reduce the dust and dirt which
may enter the burner and heat exchanger, causing improper
combustion and sooting.
45
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. 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.
Any safety devices including low water cutoffs used in conjunction
with this boiler should receive periodic (every six months)
inspection to assure proper operation. Alow water cutoff device of
the float type should be flushed every six months. Periodic checks,
at least twice a year, should be made for water leaks.
2. Loosen the flange and separate the gas train from the manifold
assembly.
3. Separate the burner from the blower adapter by first removing
the four (4) bolts and subsequently, the blower gaskets. The
blower should be free to move at this point.
More frequent inspections may be necessary depending on water
conditions.
FOR DIRECT VENT UNITS: It is necessary to loosen and slide
the rubber coupling on the blower adaptor in order to move the
blower.
The boiler-mounted gas and electrical controls have been
designed to give both dependable service and long life. However,
malfunction can occur, as with any piece of equipment. It
is therefore recommended that all components be checked
periodically by a qualified service agent for proper operation.
4. Loosen the seven bolts on the blower adapter at the base and
move the burner ground wire (Green) aside.
RELIEF VALVE
5. Lift the blower adapter and remove the manifold assembly up
from the 6 studs located on the cover plate and remove the
burner gasket.
The safety relief valve should be opened at least twice a year
to check its working condition. This will aid in assuring proper
pressure relief protection. Lift the lever at the top of the valve
several times until the valve seats properly and operates freely.
6. Remove any loose foreign material such as dust or lint with
a vacuum. Check all ports for blockage. Dislodge any foreign
material causing blockage. Remove any soot or carbon deposits
with a rag making sure to remove any lint left on the burner by
vacuuming again.
7. Reverse the steps to reassemble the unit.
8. Restore electrical power and gas supply to the boiler.
•
Put the boiler back in operation by following the Lighting and
Operating instructions in this manual.
•
Check for gas leaks and proper boiler and vent operation.
CONDENSATE REMOVAL SYSTEM
Due to the highly efficient operation of this unit, condensate is
formed during operation and must be removed by the conden-
sate drain systems. Inspect the condensate drains and tubes
at least once a month and insure they will allow the free flow of
condensate at all times. The system must be inspected more
frequently in cold weather if the drain system is located in an
area, such as along the floor, where freezing temperatures are
likely to occur. The condensate drain system must be protected
against freezing. Contact a qualified service agent to inspect
and correct the condition if freezing of the condensate lines is a
problem. The unit is equipped with a blocked flue switch which
will shut the unit off if condensate is unable to drain and backs
up in the unit. A blocked flue error will appear when sufficient
condensate accumulates for this condition.
COMBUSTION AIR FILTER
If the combustion air supply to the boiler contains dust, dirt, drywall
dust etc. a filter must be installed. An air filter is not supplied with
the boiler as shipped from the factory. The installer must provide a
filtering system in the air inlet to the boiler if dust, dirt or construction
dirt can be pulled into the boiler through the inlet air piping.
Periodically clean air filter per the manufacturer’s instructions.
The transparent drain lines and condensate drain on the bottom
of the vent collector should be visually inspected at one month
intervals for blockage, particularly in the areas of the loops in the
lines which trap a small amount of condensate, and the exit point
of the vent collector drain. Condensate in portions of the line other
than the loop area indicates a blockage in the drain line. Flush the
BLOWER COMPARTMENT
The blower compartment should be cleaned annually to remove
any dirt and lint that may have accumulated in the compartment
46
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
include a sag or low spot in the line will also form a condensate trap
which can be removed by levelling the tube and does not indicate
a blocked system.
HEATEXCHANGERPREVENTATIVEMAINTENANCE
In most water supply systems solids exist.As the water is heated, these
tendtodropoutdepositingasscaleorlime.Thisscalemustberemoved
before the heat exchanger tubes become blocked.
Inspect the metal vent drain and vent collector drain connectors
at six month intervals. Remove the hoses from the connections,
then check with a small wooden dowel or plastic rod passed up
through the metal connection to insure the passage is clear,
using caution to not bend or damage the connector. Call a
qualified service agent to inspect and correct the problem if any
obstructions are found in the connectors. Replace all hoses and
clamps immediately after inspection and before starting the boiler
in accordance with the Lighting and Operating Instructions. DO
NOT OPERATE THE BOILER UNLESS ALL CONDENSATE
DRAIN LINES ARE PROPERLY CONNECTED AND WORKING.
When a means to neutralize condensate has been installed
you must also follow operating, inspection and maintenance
procedures specified by the manufacturer of the product. Inspect
the installed device to insure that it does not cause condensate
to remain in the boiler or vent for any reason.
DELIMING
The amount of calcium carbonate (lime) released from water is
in direct proportion to water temperature and usage. The higher
the water temperature or water usage, the more lime deposits are
dropped out of the water. This is the lime scale which forms in
pipes, boilers and on cooking utensils.
The usage of water softening equipment greatly reduces the
hardness of water. However, this equipment does not always
remove all of the hardness (lime). For this reason it is recommended
that a regular schedule for deliming be maintained.
VENTING MAINTENANCE
The time between cleaning will vary from two to six months
depending upon water conditions and usage. A change
of approximately 5°F (3°C) in the normal temperature rise
through the boiler is usually an indication that scale should
be removed. For long life, copper or brass is recommended
for all valves, pipe and fittings.
It is recommended that the intake and exhaust piping of the
appliance be checked every 6 months for dust, condensate leakage,
deterioration and carbon deposits.
TUBE CLEANING PROCEDURE MECHANICAL
REMOVAL OF DEPOSITS
Establish a regular inspection schedule, the frequency depends
on the local water conditions and severity of service. Do not let
the tubes clog up solidly. Clean out deposits over 1/16” (1.6mm)
thickness.
To service heat exchanger tubes, remove return header casting on
the side opposite the water connections. Use a U.S. standard 5/8”
deep socket ratchet to remove the nuts, exposing the tube ends.
Inspect to ensure tubes are free of scale and deposits. If scaled,
remove deposits with a stiff wire brush or mechanical tube cleaner
to bare metal. Reinstall return header casting. Flush system.
Qualified service agent should follow this procedure when the
boiler’s intake and exhaust piping need cleaning:
Note: Removal of the heat exchanger is not required.
1. Turn off the electrical power, and manual gas shut-off.
• Allow boiler parts to cool before disassembly.
REPLACEMENT PARTS
2. Remove the vent pipe.
Replacement parts may be ordered through A. O. Smith dealers,
authorized servicers or distributors. Refer to the Yellow Pages for
where to call or contact (in United States) the A. O. Smith Water
Products Company, 500 Tennessee Waltz Parkway, Ashland
City, TN 37015, 1-800-433-2545 or (in Canada) A. O. Smith
Enterprises Ltd., 768 Erie Street, Stratford, Ontario, Canada
N5A 6T3, 519-271-5800. When ordering parts be sure to state
the quantity, part number and description of the item including the
complete model and serial number as it appears on the product.
Refer to the parts lists for more information.
• Check parts and chimney for obstructions and clean as
necessary.
3. Remove burner from boiler and other metal parts as required
to clean as necessary.
• Refer to parts list for disassembly aid.
4. Clean and reinstall the parts removed in steps 2 and 3.
• Be sure the vent pipe has a minimum upward pitch of 1/4"
per foot (2cm/m) of length and is sealed as necessary.
5. Restore electrical power and gas supply to boiler.
For TechnicalAssistance callA. O. Smith Technical Information
Center at 1-800-527-1953.
• Check for gas leaks and proper boiler and vent operation.
47
NOTES
48
NOTES
49
NOTES
50
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. This term is reduced to FIVE years if this boiler is used for water
heating purposes other than hydronic space heating.
a. This warranty is extended to the owner for all other parts or portion during the FIRST year following initial installation of this boiler.
b. The warranty on the repair or replacement of the part or portion will be limited to the unexpired term of the original warranty.
2. CONDITIONS AND EXCEPTIONS
This warranty shall apply only when the boiler is installed in accordance with local plumbing and building codes, ordinances and regulations, the printed
instructions provided with it and good industry practices. In addition, a pressure relief valve, certified by C.S.A. and approved by the American Society of
Mechanical Engineers, must have been installed and fresh water used for filling and make-up purposes.
a. This warranty shall apply only when the boiler is used:
(1) with inlet water temperature 120°F (49°C) and above and outlet water temperatures not exceeding the maximum setting of its operative and/
or high limit control;
(2) at water pressure not exceeding the working pressure shown on the boiler;
(3) when filled with boiler water, free to circulate at all times and with the heat exchanger free of damaging scale deposits;
(4) in a non-corrosive and non-contaminated atmosphere;
(5) in the United States, its territories or possessions, and Canada;
(6) at a water velocity flow rate not exceeding or below the boiler’s designed rates;
(7) indoor installation only.
b. Any accident to the boiler, any misuse, abuse (including freezing) or alteration of it, any operation of it in a modified form, or any attempt to repair leaks in
the heat exchanger will void this warranty.
3. SERVICE AND REPAIR EXPENSE
Under this limited warranty the warrantor will provide only a replacement part. The owner is responsible for all other costs. Such costs may include but are
not limited to:
a. Labor charges for service, removal, repair, or reinstallation of the component part;
b. Shipping, delivery, handling, and administrative charges for forwarding the replacement part from the nearest distributor and returning the claimed defective
part to such distributor.
c. All cost necessary or incidental for any material and/or permits required for installation of the replacement.
4. LIMITATIONS ON IMPLIED WARRANTIES
Implied warranties, including any warranty of merchantability imposed on the sale of this boiler under state or provincial law are limited to one (1) year duration
for the boiler or any of its parts. Some states and provinces do not allow limitations on how long an implied warranty lasts, so the above limitation may not
apply to you.
5. CLAIM PROCEDURE
Any claim under this warranty should be initiated with the dealer who sold the boiler, or with any other dealer handling the warrantor’s products. If this is not
practicable, the owner should contact:
U.S. Customers
Canadian Customers
A. O. Smith Corporation
500Tennessee Waltz Parkway
Ashland City, TN
A. O. Smith Enterprises Ltd.
P. O. Box, 310 - 768 Erie Street
Stratford, Ontario N5A 6T3
Telephone: 800-265-8520
Telephone: 800 527-1953
a. The warrantor will only honor replacement with identical or similar parts thereof which are manufactured or distributed by the warrantor.
b. Dealer replacements are made subject to in-warranty validation by warrantor.
6. DISCLAIMERS
NO OTHER EXPRESS WARRANTY HAS BEEN OR WILL BE MADE ON BEHALF OF THE WARRANTOR WITH RESPECT TO THE MERCHANTABILITY OF
THE BOILER OR THE INSTALLATION, OPERATION, REPAIR OR REPLACEMENT OF THE BOILER. THE WARRANTOR SHALL NOT BE RESPONSIBLE
FOR WATER DAMAGE, LOSS OF USE OF THE UNIT, INCONVENIENCE, LOSS OR DAMAGE TO PERSONAL PROPERTY, OR OTHER CONSEQUENTIAL
DAMAGE. THE WARRANTOR SHALL NOT BE LIABLE BY VIRTUE OF THIS WARRANTY OR OTHERWISE FOR DAMAGE TO ANY PERSONS OR
PROPERTY, WHETHER DIRECT OR INDIRECT, AND WHETHER ARISING IN CONTRACT OR TORT.
a. Some states and provinces do not allow the exclusion or limitation of the incidental or consequential damage, so the above limitations or exclusions may
not apply to you.
b. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state or province to province.
Fill in the following for your own reference. Keep it. Registration is not a condition of warranty. The model and serial number are found on the boiler’s rating plate.
Owner _________________________________________________________________________________________________________________________________
Installation Address _______________________________________________________________________________________________________________________
City and State _________________________________________________________________________Zip Code __________________________________________
Date Installed________________________________Model No. __________________________________ Serial No. ________________________________________
Dealer’s Name_______________________________________________________________ Phone No.___________________________________________________
Dealer’s Address _________________________________________________________________________________________________________________________
_______________________________________________________________________________________________________________________________________
FILL IN WARRANTY AND KEEP FOR FUTURE REFERENCE
51
500 Tennessee Waltz Parkway, Ashland City, TN 37015
Phone: 800-433-2545
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