A.O. Smith 1000 SERIES 100 User manual

1
WARNING: If the information in this
manual is not followed exactly, a fire or
explosion may result causing property
damage, personal injury or loss o f life.
— Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
— WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch; do
not use any phone in your building.
• Immediately call your gas supplier
from a neighbor ’s phone. Follow the
gas supplier ’s instructions.
• If you cannot reach your gas supplier,
call the fire department.
— Installation and service must be
performed by a qualified installer,
service agency or the gas supplier.
PRINTED 0207 212801-000
USER’S MANUAL
MODELS:
VB/VW-500, 750 AND 1000
SERIES 100/101
GAS-FIRED POWER BURNER
COPPER BOILERS FOR HYDRONIC HEATING
AND HOT WATER SUPPLY
•Installation
•Operation
•Maintenance
•Limited Warranty
MC BEE, SC., RENTON, WA.,
STRATFORD-ONTARIO, VELDHOVEN-THE NETHERLANDS,
NANJING, CHINA
w w w.hotwater.com / email: [e-mail]

2
SAFE INSTALLATION, USE AND SERVICE
Your safety and the safety of others is extremely important in the installation, use, and servicing of this boiler.
Many safety-related messages and instructions have been provided in this manual and on your own 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.
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.
IMPORTANT DEFINITIONS
•Qualified Installer: Aqualified 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.

3
GENERAL SAFETY

4
SAFE INSTALLATION, USE, AND SERVICE ....................................................................................................................................... 2
GENERAL SAFETY ................................................................................................................................................................................ 3
TABLE OF CONTENTS ......................................................................................................................................................................... 4
Installation Requirements for the Commonwealth of Mass ................................................................................................................... 5
Wiring Diagram ....................................................................................................................................................................................6-7
Schematic Diagram ................................................................................................................................................................................ 8
Lighting and Operating Instructions....................................................................................................................................................... 9
Water Temperature Regulation ............................................................................................................................................................ 10
Control System ................................................................................................................................................................................ 10-11
Operating Sequence ............................................................................................................................................................................. 11
UIM Operating Procedures .................................................................................................................................................................. 12
Operating Setpoint Adjustment Procedure .......................................................................................................................................... 14
TROUBLESHOOTING IGNITION SYSTEM ......................................................................................................................................... 16
Troubleshooting Gas Valve.............................................................................................................................................................. 17
PREVENTATIVE MAINTENANCE ........................................................................................................................................................ 17
Main Burners .................................................................................................................................................................................... 17
Relief Valve ...................................................................................................................................................................................... 18
Combustion Air Filter ....................................................................................................................................................................... 18
Blower Compartment ........................................................................................................................................................................ 18
Burner Maintenance ......................................................................................................................................................................... 18
Condensate Removal System ......................................................................................................................................................... 18
Venting Maintenance ........................................................................................................................................................................ 19
Heat Exchanger Preventive Maintenance ....................................................................................................................................... 19
Tube Cleaning Procedure................................................................................................................................................................ 19
REPLACEMENT PARTS ...................................................................................................................................................................... 19
LIMITED WARRANTY .......................................................................................................................................................................... 23
CONTENTS
INTRODUCTION
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.
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.

5
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.
INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS

6
CONNECTION DIAGRAM

7

8
SCHEMATIC DIAGRAM
VB/VW-500, 750 & 1000 SCHEMATIC DIAGRAM

9
LIGHTING & OPERATION INSTRUCTIONS FOR MODELS VB/VW 500, 750 AND 1000:

10
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.
The boiler should be located in an area that is inaccessible to
the general public.
TABLE 1. Risk of Scalds.
Temperature Time to Produce 2nd & 3rd
Setting Degree Burns on Adult Skin
Over 170°F (77°C) Nearly instantaneous
160°F (71°C) About 1/2 second
150°F (66°C) About 1-1/2 seconds
140°F (60°C) Less than 5 seconds
130°F (54°C) About 30 seconds
120°F (49°C) or less More than 5 minutes
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) differential between the boiler’s inlet and
outlet (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 are needed.
Please contact your A.O. Smith qualified service agent.
CONTROL SYSTEM
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)
• Power Distribution Board (PDB)
• User Interface Module (UIM)
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.
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.
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
WATER TEMPERATURE REGULATION
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 low-
est possible temperature setting that satisfies your hot water
needs, a means such as a mixing valve shall 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.
Follow the manufacturer’s instructions for installation of the valves.
Before changing the thermostat setting on the hot water system
controller, see Table 1.
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