Page 2 - SAFE INSTALLATION, USE AND SERVICE; WARNING; IMPORTANT DEFINITIONS; Qualified Installer:; provided by the manufacturer.
2 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 injur...
Page 3 - GENERAL SAFETY
Page 4 - DIMENSION AND CAPACITY DATA
4 Minimum clearances to combustibles: • 4” (102mm) rear • 0” (0mm) top & sides • 6” (152mm) vent TABLE 1. - GAS AND ELECTRICAL CHARACTERISTICS Manifold Pressure Maximum Supply Pressure Minimum Supply Pressure Model Type of Gas Inches W.C. kPa Inches W.C. kPa Inches W.C. kPa VB/VW-500, 750, 1000 ...
Page 5 - CAPACITY AND FLOW DATA
5 CAPACITY AND FLOW DATA TABLE 3. RECOVERY CAPACITIES. TABLE 4. PUMPING PERFORMANCE GUIDE. VB MODELS - FLOW, HEAD LOSS AND TEMPERATURE RISE 20F° (11°C) t 30F° (17°C) t 40F° (22°C) t 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 P FT P m T °F T °...
Page 7 - shall be maintained.; re turning 120°F (49°C) water from the remote storage tank to
7 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. This boiler must be connected to a grounded metal, permanent wiring system, or an equipment groun...
Page 8 - CONTROL COMPONENTS
8 THE CONTROL SYSTEM 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 lo...
Page 9 - HOT WATER SUPPLY BOILER-VW; TEMPERATURE PROBES; INLET AND OUTLET TEMPERATURE PROBES; PRESSURE RELIEF VALVE; Explosion Hazard; CAUTION; Pressure Relief Valve discharge pipe must; Wa
9 WATER TEMPERATURE LIMIT CONTROLS 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 2...
Page 10 - GENERAL; REQUIRED ABILITY; Low Water; PANELS AND COVERS
10 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...
Page 11 - Breathing Hazard - Carbon Monoxide Gas; UNUSUALLY TIGHT CONSTRUCTION
11 FIGURE 8. CHEMICAL VAPOR CORROSION Boiler corrosion and component failure can be caused by the heating and breakdown of airborne chemical vapors. Spray can propellants, cleaning sol vents, refrigerator and air conditioning refrig erants, swimming pool chemicals, calcium and sodium chloride (water...
Page 13 - AIR FROM OTHER INDOOR SPACES; The confined space should be provided with two permanent
13 AIR FROM OTHER INDOOR SPACES FIGURE 9E. The confined space should be provided with two permanent openings, one commencing within 12 inches (300 mm) of the top and one commencing within 12 inches (300 mm) of the bottom of the enclosure. See Figure 9E. Each opening should communicate directly with ...
Page 14 - TERMINATION CLEARANCES SIDEWALL POWER VENT; POWER VENT
14 TERMINATION CLEARANCES SIDEWALL POWER VENT V X VENT TERMINAL AIR SUPPLY INLET AREA WHERE TERMINAL IS NOT PERMITTED v v A G V FIXED CLOSED FIXED CLOSED OPERABLE OPERABLE V C B B B B F B V V A J V H M X X V V K B E D L POWER VENT (using room air for combustion) EXTERIOR CLEARANCES FOR SIDEWALL VENT...
Page 15 - TERMINATION CLEARANCES SIDEWALL DIRECT VENT; DIRECT VENT
15 TERMINATION CLEARANCES SIDEWALL DIRECT VENT V X VENT TERMINAL AIR SUPPLY INLET AREA WHERE TERMINAL IS NOT PERMITTED v v A G V FIXED CLOSED FIXED CLOSED OPERABLE OPERABLE V C B B B B F B V V A J V H M X X V V K B E D L DIRECT VENT (using outdoor air for combustion) EXTERIOR CLEARANCES FOR SIDEWALL...
Page 16 - VENTING; ALL ELECTRICAL POWER AND GAS MUST BE TURNED OFF; SPECIAL INSTALLATION CONSIDERATIONS; Vertical Termination; GENERAL EXHAUST VENT INSTALLATION PROCEDURE; CONNECTING VENT TO BOILER
16 VENTING 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. SPECIAL INSTALLATION CONSIDERATIONS This boiler is a category IV appliance that can be vented us...
Page 17 - VENTING SUPPORTS; DO NOT rivet or screw the straps to the conduit or other wise; VERTICAL INSTALLATION REQUIREMENTS
17 VENTING SUPPORTS 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...
Page 19 - DIRECT VENT INSTALLATION REQUIREMENTS; R E Q U I R E M E N T S ” s e c t i o n f o r t h e e x h a u s t i n g o f f l u e; IMPORTANT; The Air-Intake System (AIS) must ter minate with the venting; INSTALLATION OF CARBON MONOXIDE DETECTORS
19 DIRECT VENT INSTALLATION REQUIREMENTS Follow the guidelines in the “HORIZONTAL INSTALLATION R E Q U I R E M E N T S ” s e c t i o n f o r t h e e x h a u s t i n g o f f l u e products. IMPORTANT The labels in the Direct Vent Kit must be affixed to the boiler in locations specified by the instruc...
Page 21 - assures no recirculation of flue gases.
21 FIGURE 12B. DIRECT VENT, VERTICAL VENT TERMINATION WITH HORIzONTAL INTAKE. FIGURE 12C. DIRECT VENT USING TWT WITH VERTICAL INTAKE. Option B (Figures 12B & 12C) assures no recirculation of flue gases. 70 EQUIVALENT FEET (27.4m) OF VENTING (MAX.) AL 29-4C ® HORIzONTAL AIR INTAKE PVC PIPE 70 EQU...
Page 22 - SYSTEM INSTALLATION; FOR HOT WATER HEATING BOILERS - VB MODELS
22 SYSTEM INSTALLATION GENERAL 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...
Page 25 - DANGER; TYPICAL
25 FIGURE 13. TYPICAL PRIMAR Y, SECONDAR Y PIPING. • INST ALL IN ACCORDANCE WITH ALL LOCAL CODES. • WHEN BLOW DOWN V AL VE IS REQUIRED, INST ALL IN PLACE OF THE DRAIN V AL VE SHOWN. DANGER TEMPER ATUR E SETTIN G SH OU LD N OT EXC EED SAFE USE TEMPERA TURE AT FIXTURES. IF H IGH ER PREHEA T TEMPER A T...
Page 26 - ATER SUPPL
26 DANGER TEMPERA TURE SETTI NG SHO ULD NO T EXCEED SAFE USE TEMPERA TURE AT FIXTURES. IF HIGHER PREHEA T TEMPERA TURES ARE NECESSAR Y T O O BT AI N ADEQ UA TE BOOSTER OUTPUT , ADD AN ANTI-SCALD V AL VE FOR HOT W ATER SUPPLIED T O FIXTURES, SEE T ABLE 8. ONE VF (MODEL VW) HOT W ATER SUPPL Y BOILER W...
Page 28 - WIRING; Label all wires prior to disconnection when servicing controls.; N O T E : Ta n k p r o b e s a r e n o t p r o v i d e d o n V B m o d e l s ,
28 WIRING Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.Verify proper operation after servicing. Strict adherence to the wiring diagrams is required to prevent constant pump operation when the system controller is satisfied. ...
Page 29 - SUGGESTED PIPE SIzING TABLES; TABLE 7. Suggested Pipe Size For Multiple Gas
29 SUGGESTED PIPE SIzING TABLES TABLE 7. Suggested Pipe Size For Multiple Gas Appliances (Propane Gas). Nominal Maximum Capacity of Pipe in BTU/hr and kW for Gas Pressures of 14 in. W .C. (0.5 psi) or Less and Iron Pipe a Pressure Drop of 0.5 in. W .C. (based on 0.60 Specific Gravity Gas w/Heating V...
Page 30 - WIRING DIAGRAM
Page 33 - OPERATION; If upstream
33 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 ...
Page 34 - water temperatures are reached.; WATER TEMPERATURE REGULATION; personal injury and/or death. The temperature at which injury
34 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. Water Temperature Time to ...
Page 37 - ADJUSTMENT; There must be sufficient load to operate the boiler at high fire to; SETTING OF THE TEST MODE; Set boiler to the “Test Mode High,” as described above, to; CONTROL SYSTEM; system. The User Interface Module (UIM) communicates with the; communications cables should never be connected to
37 ADJUSTMENT There must be sufficient load to operate the boiler at high fire to perform the following adjustments. Start the boiler and observe proper operating parameters for the system. Required Tools: TORX ® T40 or 5mm hex wrench 3mm or 7/64in hex wrenchCombustion analyzerThe VF 500, 750, and 1...
Page 38 - INPUTS TO MCB; Temperature probes
38 INPUTS TO MCB 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). MRHL (Manual Reset HIGH LIMIT): The MRHL is a hi-limit switch located inside the outlet probe. ...
Page 39 - OPERATING SEQUENCE; TEMPERATURE SETPOINTS (SYSTEM CONTROL ALGORITHM)
39 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 configur...
Page 40 - UIM OPERATING PROCEDURES; System Status Screen:
40 UIM OPERATING PROCEDURES FIGURE 20. UIM, USER INTERFACE MODULE 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-a...
Page 41 - Description of FCB control states:; OPERATING SETPOINT ADJUSTMENT PROCEDURE; AUTO HIGH LIMIT SETPOINT ADJUSTMENT PROCEDURE/
41 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...
Page 42 - Post Circulate Delay Time:
42 Use the following procedure to change the automatically resettable High Limit Setpoint:1. Press the MENU key. 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. 5. Press t...
Page 43 - • Up and Down Keys:; UIM LED’s; The faults create different types of system lockouts (shut
43 • Up and Down Keys: 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 ...
Page 44 - TROUBLESHOOTING IGNITION SYSTEM; FAULT DISPLAYED
44 TROUBLESHOOTING IGNITION SYSTEM Fault Messages and Lockout Status (* = stage number: 1, 2, 3, or 4) FAULT DISPLAYED DESCRIPTION RED LED LOCKOUT “Display Fail” Communications with UIM interrupted Continuous Auto Reset Check communication cable to UIM. Try moving to other Internal Communications co...
Page 45 - TROUBLESHOOTING GAS VALVE; PREVENTATIVE MAINTENANCE; FIGURE 21. BURNER FLAMES; MAIN BURNER
45 TROUBLESHOOTING GAS VALVE Problem: Non-linear CO 2 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: Unstable CO 2 level at minimum load The minimum load (...
Page 48 - NOTES
Page 51 - LIMITED WARRANTY
51 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 ...
