A.O. Smith VB/VW-500 - Manual (Page 6)

6
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.
Detailed installation diagrams are found in this manual. These
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.
The factory warranty will be void if the boiler(s) have been
improperly installed or operated.
General ...................................................................................... 18
Hot Water Heating (Hydronic) Equipment .................................. 18
Internal Contaminants ................................................................ 19
Hot Water Supply System General Water Line Connections ...... 19
Hard Water Conditions ............................................................... 19
Thermal Expansion (Closed System). ........................................ 19
Remote Probe Installation Procedure .................................... 19-20
Gas Connections .................................................................. 20-22
Gas Supply Line Sizing .............................................................. 22
Wiring ........................................................................................ 22
SUGGESTED PIPE SIZING TABLES ............................................. 23
CONNECTION DIAGRAM ......................................................... 24-25
SCHEMATIC DIAGRAM ................................................................. 26
OPERATION ................................................................................... 27
Important ................................................................................... 27
General ...................................................................................... 27
Filling and Purging for Heating Boiler Installation ........................ 27
Filling for Hot Water Supply Boiler Installation ............................ 27
Purging Gas Line ....................................................................... 27
Inlet Gas Pressure ..................................................................... 27
Water Temperature Regulation .................................................. 28
Manifold Pressure Connections ................................................. 28
Dipswitches ................................................................................ 29
LIGHTING AND OPERATING INSTRUCTIONS ............................. 30
Adjustment ................................................................................. 31
Setting of the Test Mode ............................................................ 31
Control System .......................................................................... 31
Operating Sequence .................................................................. 32
UIM Operating Procedures ........................................................ 33
Operating Setpoint Adjustment Procedure ............................ 35-36
TROUBLESHOOTING IGNITION SYSTEM ................................... 37
Troubleshooting Gas Valve ........................................................ 38
PREVENTATIVE MAINTENANCE .................................................. 38
Main Burners ........................................................................ 38-39
Relief Valve ................................................................................ 39
Combustion Air Filter .................................................................. 39
Blower Compartment ................................................................. 39
Burner Maintenance ................................................................... 39
Condensate Removal System .................................................... 39
Venting Maintenance ................................................................. 40
Heat Exchanger Preventive Maintenance ................................... 40
Tube Cleaning Procedure .......................................................... 40
REPLACEMENT PARTS ................................................................ 40
LIMITED WARRANTY .................................................................... 43
AL 29-4C ® is a registered trademark of Allegheny Ludlum
Corporation.
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
followed in all cases. Authorities having jurisdiction should be
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
National Electric Code, NFPA 70.
SAFE INSTALLATION, USE, AND SERVICE ................................. 2
GENERAL SAFETY .......................................................................... 3
DIMENSION AND CAPACITY DATA ............................................ 4-5
TABLE OF CONTENTS ................................................................... 6
INTRODUCTION ............................................................................ 6-7
Grounding Instructions ................................................................. 7
Inlet Water Considerations .......................................................... 7
Correct Gas ................................................................................. 7
Precautions ................................................................................... 7
Liquefied Petroleum Gas Models .................................................
High Altitude Installations ............................................................ 7
Field Installed Components ......................................................... 7
Panels and Covers ...................................................................... 7
FEATURES ........................................................................................ 7
The Control System .................................................................... 8
Hot Surface Igniter ...................................................................... 8
Blocked Exhaust Pressure Switch .............................................. 8
Blower Prover Switch .................................................................. 8
Optional Low/High Gas Switch ................................................... 8
Water Flow Switch ...................................................................... 8
Flame Sensor .............................................................................. 8
Water Temperature Limit Controls .............................................. 9
On/Off Switch ............................................................................... 9
Circulating Pump ......................................................................... 9
Remote Probe .............................................................................. 9
Low Water Cutoff (Optional) ....................................................... 9
Safety Relief Valve ................................................................. 9-10
GENERAL
Required Ability .......................................................................... 10
Location ...................................................................................... 10
Panels and Covers ............................................................... 10-11
Chemical Vapor Corrosion ........................................................ 11
Installation Clearances ............................................................... 11
Leveling ...................................................................................... 11
Air Requirements .................................................................. 11-12
VENTING .................................................................................... 12
Special Installation Considerations . ......................................... 12
Venting System Using AL 29-4C® ........................................... 12
General Exhaust Vent Installation Procedure .......................... 12
Connecting Vent to Boiler ......................................................... 12
Venting Supports ........................................................................ 13
Vertical Installation Requirements ............................................. 13
Horizontal Installation Requirements .................................... 13-14
Direct Vent Installation Requirements ....................................... 15
Installation Requirements for the Commonwealth of Mass ...... 15
SYSTEM INSTALLATION .............................................................. 18
CONTENTS
INTRODUCTION