A.O. Smith VW 1000 Quick start guide

Brand: A.O. Smith

Model: VW 1000

Type: Quick start guide

This manual is also suitable for

Start-up Instructions

VB/VW 500/750/1000

Series 100/101

Before starting the boiler, please review the boilers instruction manual (AOS Part Number 212800) supplied with the boiler. This

is a powered combustion copper tube boiler. Please contact an authorized A.O. Smith representative before starting the unit.

Ensure that the water piping, gas line, controls, and venting have been installed per the instruction manual.

Gas supply lines should be sized in accordance with the current edition of National Fuel Gas Code (ANSI Z223.1/NFPA 54) or

CAN/CSA B149.1 The Canadian Natural Gas and Propane Installation Code.

Make sure the boiler is not damaged. If the unit is damaged, contact an A.O. Smith representative for service or replacement

parts prior to starting the boiler.

This boiler is equipped with a Modulating EMC 5000 control system. The EMC 5000 displays the system status and errors that may

occur during normal operation. For full details on the controls, please refer to the Installation Manual supplied with the boiler. The

boiler must be installed according to the instructions provided with the unit. Failure to do so will void the warranty.

The following test equipment should be on hand: (all test equipment must be acclimated to ambient temperature before calibration

and use.)

• AcombustionanalyzercapableofmeasuringCOandCO

or O

• Adigitalmanometerorpressuregaugescapableofaccuratelydisplaying0–15(±.01)inchesofwatercolumn.

• Combinationvolt/ammeter

• TORX®T40or5mmhexwrench–forsettinggasmixtureatgasvalve

• 3mmor7/64inhexwrench–forsettinggasmixtureatgasvalve

I. Verify utilities

• Ensurethatthewaterpiping,gasline,controls,andventinghavebeeninstalledpertheinstructionmanual.

• Becertainthatthesystemisfullofwater,thatairispurgedfromalllines,theboiler,andstoragetank.

• Ensurethatnoleaksarepresentandthatallsupplyandreturnwatervalvesareopen.

• Upstreamgasvalveshouldremaincloseduntilstartup.

II. Component Sequence Verication

• Ensurethatthepowersupplymeetstheserequirements:singlephase,Minimum:108VACRMS;Maximum:132VACRMS

and is on a dedicated circuit breaker with separate neutrals and grounds.

• Ensureallcontrolwiringisruninadedicatedconduitperinstructionmanual.

• Performpowersupplytestoutlinedintheinstructionmanual.

• Ensurethattheupstreammanualgasvalveoftheboilerisopen.

Priortoturningonthegas,propersequenceofmostofthesystemcanbeveried.Withthewaterturnedon,andthegasturned

off by the downstream manual valve, start the system and allow it to run through a heating cycle. It should stop when it checks for

theameanddeclareafault.Thiswillverifythatthepump,owswitch,igniter,variablefrequencydrive,modulatinggasvalve,

blower and low/ high blower prover switches are all functioning properly.

III. Initial Boiler Set-up Verication

• Drillamaximum7/16”holeinthesideoftheventbootteeapproximately8”frombackpaneltoinsertthegasanalyzerprobe.

The hole must be sealed upon completion of the start-up testing.

• Openthedownstreammanualgasvalvetotheboilerandpurgeairfromtheline.

PRINTED0608 212936-002

• Measuretheincominggaspressure.-Minimuminletgassupplypressureof4”w.c.andmaximumis11.0fornaturalgasor

8”w.c.minand13.8maxforpropane.Themaximumvaluespeciedmustnotbeexceededunderbothloadandnoload

conditions.Ifthisconditioncannotbeobtainedapositivelock-uptypepressureregulatorMUSTbeinstalledapproximately

vefeetawayfromthegasvalveoftheboilerandpertheregulatormanufacture’sinstructions.

• Checkallgassupplylinesforleaks.

• Checkthatallventingisproperlyinstalledinaccordancewiththeventingsectionoftheinstructionmanual.

Follow the lighting and operating instructions in the Instruction Manual.

IV. Boiler Start-Up

• Starting the boiler for the rst time

-Theboileristestedatthefactoryandshouldstartproperlyifinstalledinaccordancewiththeboiler’sinstructionmanual.

- Before starting the boiler, refer to the temperature set-point procedure section in the boilers instruction manual.

 -Turnontheboiler’son/offswitch.Ensuretheoperatingsetpointissethighenoughtoactivateacallforheat.Ifanexternal

controlisusingtheboiler’sEnable/Disablecircuit,ensurethattheexternalcontrol’scontactsareclosed.Ifthereisno

externalcontrol,ensurethatthetwowiresprovidedforthiscircuitarewire-nuttedtogetherinthejunctionboxontheback

oftheboiler.Refertothewiringdiagramontheboiler.

- Allow the unit to run for at least 10 minutes before proceeding with the combustion analysis. Take a combustion sample and

record CO and CO

or O

readings.

• 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20minutesbeforedefaultingtotheMOD(modulation)mode.

• MAXIMUM FIRE ADJUSTMENT

- Combustion sample

 -Firstsetboilertothe“TestModeMax,”asdescribedabove,toachievemaximumringrateoftheboiler.Checkcombustion

readingsusingacombustionanalyzer.Ifcombustionreadingsarenotinaccordancewiththechartbelowadjustasfollows:remove

theat,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owandachievethedesiredCO

level. See Table referenced below for correct settings.

TherewillbeaslighttimedelaybetweentheadjustmentandtheresponseoftheCO

measuringinstrument.Adjustthesettings

insmall1/16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 8 inches from the rear boiler.

IMPROPERADJUSTMENTCANCAUSEINCOMPLETECOMBUSTIONRESULTINGINDEATH.

• MINIMUM FIRE ADJUSTMENT - Combustion sample

 -Nextsetboilertothe“TestModeMin,”asdescribedabove,toachieveminimumringrateoftheboiler.Checkcombustion

readingsusingacombustionanalyzer.Ifcombustionreadingsarenotinaccordancewiththechartshownbelowadjustas

follows:removethemetal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regassettingtoachievetheCO

level prescribed

inbelowreferencetable.Note:TherotationoftheLowFireadjustmentisoppositeoftheHighFireasfollows:Clockwise

rotationincreasesgasow,counterclockwiserotationdecreasesgasow.Adjustmentstotheoffsetpressureregulators

shouldnotexceed1/16incrementsatatimebeforeallowingthereadingstorespondandstabilize.Afterproperlowre

offsetadjustmentismade,reinstalltheslottedcapontheregulator.

 Followingallgasvalveadjustments,checkforproperlight-offandverifycorrectfuel/airmixduringtestmodeprocedureprescribedabove.

 Ifadjustmentshavebeenmade,repeatthecombustionsamplingusingthe“TestMode”proceduretoinsurethatthereadingsremain

withintheranges.IfthereadingsarenotinaccordancerepeattheHighandLowreadjustmentprocedure.

IMPORTANT!! The Min Mode and Max Mode are used for checking combustion during start up. Return boiler to Mod Mode after

checking combustion.

• Combustion readings should fall within the ranges listed in the table below.

Combustion Samples Acceptable Range

% CO

, for Natural Gas @ max input 8.0% - 9.5%

% CO

, for Propane Gas @ max input 8.5% - 10.0%

CO PPM < 200 PPM

% CO

, for Natural Gas @ min input 6.5%-7.5%

% CO

, for Propane Gas @ min input 7.5%-8.5%

CO PPM < 100 PPM

• Ifcombustionmeasurementsarenotintherangespecied,pleaserepeattheSettingofthetestmodeandMaximumand

Minimumreadjustmentprocedureasdescribedpreviously.

Start Up Record

Start-upDate______________________

ModelNumber_____________________

SeriesNumber______________________

Gastype:___________

Powersupplyvoltage:Hot/Gnd______VAC,Hot/Neutral______VAC,Neutral/Gnd______VAC

Maximum Fire Minimum Fire

InletGasSupplyPressureInchW.C.

ManifoldPressureInchW.C.

CO PPM

BlowerRPMs

Flue Gas Temp (°F)

StackPressureInchW.C.

DISPOSITION

AlltestsandvaluesspeciedmustmeetspecicationspriortoissuingthisStart-upcerticate.Foranydiscrepancies,please

explainbelowwhatactionwastakentocorrecttheproblem.

NOTIFICATION

Alltestandvaluesspeciedmustmeetspecicationspriortoissuingthisstart-upcerticate.Foranyoftheeldtestsperformed,

explainbelowwhatactionwasperformedtocorrecttheproblem.Theownerhasbeennotiedthatcorrectionsmustbemadeto

this installation. The owner acknowledges that changes must be made within 30 days, prior to start up being completed.

RequiredSignatureofOwner Date

STATEMENT OF COMPLIANCE

I, the undersigned, certify that the product listed and described above has been started in accordance with this

form and the literature provided, (Instruction Manual part number 212800) and that all measured values and

requirementsarewithin the manufacturer’s specications. If thisunit does not meet all start-upcriteriain this

document, DO NOT LEAVE UNIT IN OPERATION. SEVERE PERSONAL INJURY, PROPERTY DAMAGE OR

EQUIPMENTDAMAGEMAYOCCUR.Iftheboilerisdamagedduetoanycriterianotbeingmet,WARRANTYmay

not cover damaged parts or any labor allowances.

__________________________________ __________________

Required Signature of Start-up Agent Date

__________________________________ __________________

Required Signature of Owner, contractor or installer Date

For additional information please refer to the User’s Manual supplied with the boiler or contact:

A.O. Smith Technical Services at 1-800-527-1953

7 a.m. to 7 p.m. Central Time

Our Internet Site is another source of information 24 hours a day.

http://www.aosmithwaterheaters.com

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A.O. Smith VW 1000 Quick start guide

Brand: A.O. Smith

Model: VW 1000

Type: Quick start guide

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A.O. Smith VW 1000 Quick start guide

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