A.O. Smith 3400 manual

XP BOILER Instruction Manual PRINTED IN THE U.S.A. 071 1 320741-002 Thank you for buying this energy efcient boiler . We appreciate your condence in our products. MODEL S: XB/XW 1 000, 1300, 1700 2000, 2600, 3400 SERIES 100/101 INST ALLA TION - OPERA TION - MAINTENANCE - LIMITED W ARRANTY 25589 Highway 1 McBee, SC 29101 W ARNING: If the infor[...]

2 T ABLE OF CONTENTS T ABLE OF CONTENTS .......................................................................... 2 SAFE INST ALLA TION, USE AND SERVICE .......................................... 3 GENERAL SAFETY ................................................................................ 4 INTRODUCTION ........................................[...]

3 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.[...]

4 GROUNDING INSTRUCTIONS This boiler must be grounded in accordance with the National Electrical Code, Canadian 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 grounding conductor must be r[...]

5 This Instruction Manual covers XP Boiler models XB/XW 1000, 1300, 1700, 2000, 2600, 3400 - Series 100/101. The instructions and illustrations contained in this Instruction manual will provide you with troubleshooting procedures to diagnose and repair common problems and verify proper operation. MODEL IDENTIFICA TION Check the rating plate afxe[...]

6 DIMENSIONS AND CAP ACITY DA T A T ABLE 1. ROUGH IN DIMENSIONS (SINGLE) Models XB/XW-1000 XB/XW -1300 XB/XW-1700 Dimensions inches mm inches mm inches mm Flue Outlet Diameter 6 152 8 152 8 203 Air Intake Diameter 6 152 6 152 8 203 W ater Inlet 2 inch NPT 2 1/2 inch NPT W ater Outlet 2 inch NPT 2 1/2 inch NPT Gas Inlet 2 inch NPT 2 inch NPT A 47 1 [...]

7 T ABLE 3. ROUGH IN DIMENSIONS (DOUBLE) Models XB/XW-2000 XB/XW -2600 XB/XW-3400 Dimensions inches mm inches mm inches mm Flue Outlet Diameter 8 203 8 203 10 254 Air Intake Diameter 8 203 8 203 10 254 W ater Inlet 3 inch NPT 4 inch NPT W ater Outlet 3 inch NPT 4 inch NPT Gas Inlet 2 inch NPT 3 inch NPT A 47 1 194 49 1245 57 1448 B 78 1981 80 2032 [...]

8 MODELS (XB/XW) INPUT MBH GROSS OUTPUT MBH (NOTE 1) NET I=B=R RA TINGS W A TER MBH (NOTE 2) MAX MIN 1000 920 100 856 744 1300 1300 130 1209 1051 1700 1700 170 1581 1375 2000 2000 100 1860 1617 2600 2600 130 2418 2103 3400 3400 212 3162 2750 RA TINGS T ABLE 5. IBR RA TINGS Notes: 1. The ratings are based on standard test procedures prescribed by th[...]

9 FLOW , HEAD AND TEMPERA TURE RISE T ABLE 7. XB MODELS - FLOW , HEAD AND TEMPERA TURE RISE Models Input (Btu/hr) Output (Btu/hr) W ater Flow T emperature Rise - ΔT °F Flow Rate 20 30 40 Maximum Minimum XB-1000 920,000 855,600 GPM 86 56 43 86 43 LPM 325 2 11 162 325 162 ΔP FT 26 12 7 26 7 ΔP M 7.9 3.7 2.1 7.9 2.1 XB-1300 1,300,000 1,209,000 GPM[...]

10 FEA TURES AND COMPONENTS FIGURE 3. SINGLE HEA T EXCHANGER BOILER COMPONENTS[...]

11 FIGURE 4. DOUBLE HEA T EXCHANGER BOILER COMPONENTS[...]

12 COMPONENT DESCRIPTION 1. Front access door: Provides access to the gas train, burner controllers and the heat exchanger . 2. Air Filter Box: Allows for the connection of the PVC air intake pipe to the boiler through a standard PVC adapter . It uses a lter to prevent dust and debris from entering the boiler . 3. Automatic air vents: Designed t[...]

13 FIGURE 7. LOW/HIGH GAS PRESSURE SWITCH GAS V AL VE The gas valve is a normally closed servo regulated gas valve. The valve opens only when energized by the burner control and closes when the power is removed. The burner control supplies 24 volts to the gas valve during operation. FIGURE 8. GAS V AL VE W A TER FLOW SWITCH The water ow switch a[...]

14 FLAME SENSOR Each burner is equipped with a ame sensor to detect the presence of the burner ames at high and low re conditions. If no ame is sensed, the gas valve will close automatically . The voltage sensed by the ame sensor will also be displayed on the Burner Screen. FIGURE 10. FLAME SENSOR W A TER TEMPERA TURE LIMIT CONTROLS [...]

15 GENERAL If the system is to be lled with water for testing or other purposes during cold weather and before actual operation, care must be taken to prevent freezing of water in 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 . F[...]

16 CIRCULA TING PUMP A circulating pump is used when a system requires a circulating loop or there is a storage tank used in conjunction with the boiler . Install in accordance with the current edition of the National Electrical Code, NFP A 70 or the Canadian Electrical Code, CSA C22.1. All bronze circulating pumps are recommended for use with comm[...]

17 A discharge pipe from the relief valve should terminate at an ad equ ate oo r drain. Do not thread, plug, or cap the end of drain line. 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[...]

18 T ABLE 8. SINGLE UNIT INST ALLA TION, SUGGESTED GAS PIPE SIZING. MAXIMUM EQUIV ALENT PIPE LENGTH (IN FEET). BTU Input 2” 2-1/2” 3” 4” Nat Pro Nat Pro Nat Pro Nat Pro 920,000 70 150 175 ----- ----- ----- ----- ----- 1,300,000 40 100 100 200 ----- ----- ----- ----- 1,700,000 20 60 70 150 200 ----- ----- ----- 2,000,000 20 50 50 100 150 ---[...]

19 • Auto body shops • Plastic manufacturing plants • Furniture renishing areas and establishments • New building construction • Remodeling areas Common household products, pool and laundry products may contain uorine or chlorine compounds. When these chemicals come in contact with the boiler , they react and can form strong acids. [...]

20 T ABLE 10. SUGGESTED PIPE SIZE FOR MUL TIPLE GAS APPLIANCES (NA TURAL 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 Specic Gravity Gas w/Heating V alue of 1,000 BTU’s/Ft3) Size Length of Pipe in Feet (Meters) (Inches) 10[...]

21 GENERAL REQUIREMENTS REQUIRED ABILITY Installation or service of this boiler requires ability equivalent to that of a licensed trades man in the eld involved. Plumbing, air supply , venting, gas supply , and electrical work are re quired. LOCA TION When installing the boiler , consideration must be given to proper location. The location selec[...]

22 LEVELING Because this unit is a Category IV appliance it produces some amounts of condensation. The unit has a condensation disposal system that requires this unit to be level to properly drain. Each unit should be checked to be certain that it is level prior to starting the unit. If the unit is not level, obtain and insert shims under the feet [...]

23 CONFINED SP ACE A conned space is one whose volume is less than 50 cubic feet per 1,000 Btu/hr (4.8 cubic meters per kW) of the total input rating of all appliances installed in the space. Openings must be installed to provide fresh air for combustion, ventilation and dilution in conned spaces. The required size for the openings is depende[...]

24 The conned space shall 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 shall communicate directly with the outdoors. See Figure 20. Each duct opening shall have a minimum free area of 1 square inch[...]

25 VENTING V ent sizing, installation and termination should be in accordance with this installation manual. This boiler must be vented using PVC/CPVC or Stainless Steel materials. All electrical power and gas must be turned of f prior to any installation of the venting system. VENT INST ALLA TION CONSIDERA TIONS This boiler is a category IV applia[...]

26 VENT AND AIR PIPE INST ALLA TION 1. Measure from the boiler level to vent. Refer to the T able 14 on Page 36 for the allowable lengths. 2. Prepare pipes to the required lengths and deburr the inside and outside of the pipe ends. Chamfer outside the pipe end to ensure even cement distribution when joining. 3. Clean all pipe ends and ttings usi[...]

27 (30.5 m). A maximum of three 90° elbows can be used. Minimum vertical vent is 7 equivalent feet (2.1 m) for direct vent installations. Standard minimum vertical vent length is 7 feet (2.1 m). See Figure 25, Figure 28 thru Figure 30 for differences between standard and direct vent installations. 3. An AL 29-4C ® V ent V ertical V ent T erminal [...]

28 FIGURE 25. VERTICAL VENTING FIGURE 26. HORIZONT AL VENTING MODELS (XB/XW) VENT KIT NUMBERS (RAIN CAP) 1000 320884-000 1300 320884-001 1700 320884-001 2000 320884-001 2600 320884-001 3400 320884-002 MODELS (XB/XW) VENT KIT NUMBERS (TEE) 1000 321765-000 1300 321765-001 1700 321765-001 2000 321765-001 2600 321765-001 3400 321765-002[...]

29 FIGURE 27. DIRECT VENT HORIZONT AL FIGURE 28. DIRECT VENT VERTICAL MODELS (XB/XW) VENT KIT NUMBERS (TEE) AIR INT AKE KIT NUMBERS (ELBOW) 1000 321765-000 321764-000 1300 321765-001 321764-000 1700 321765-001 321764-001 2000 321765-001 321764-001 2600 321765-001 321764-001 3400 321765-002 321764-002 MODELS (XB/XW) VENT KIT NUMBERS (RAIN CAP) AIR I[...]

30 FIGURE 29. DIRECT VENT , VERTICAL VENT HORIZONT AL INT AKE FIGURE 30. DIRECT VENT , HORIZONT AL VENT VERTICAL INT AKE MODELS (XB/XW) VENT KIT NUMBERS (RAIN CAP) AIR INT AKE KIT NUMBERS (ELBOW) 1000 320884-000 321764-000 1300 320884-001 321764-000 1700 320884-001 321764-001 2000 320884-001 321764-001 2600 320884-001 321764-001 3400 320884-002 321[...]

31 TERMINA TION CLEARANCES SIDEW ALL POWER VENT V X VEN T TERMINAL AIR SUPPL Y INLE TA RE A WHERE TERMINAL IS NO T 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 SIDEW ALL VENT TERMINA TION FIGURE 31. POWER VENT V ent [...]

32 TERMINA TION CLEARANCES SIDEW ALL DIRECT VENT FIGURE 32. DIRECT VENT V ent terminal clearances for “Direct Vent” installations. Direct V ent congurations use outdoor air for combustion. CANADIAN INST ALLA TIONS 1 US INSTALLA TIONS 2 CANADIAN INST ALLA TIONS 1 US INST ALLATIONS 2 A Clearance above grade, veranda, porch, deck or balcony 12 [...]

33 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 ([...]

34 DIRECT VENT : HORIZONT AL TERMINA TION Gas vent extending through an exterior wall must not terminate adjacent to a wall or below building extensions such as eaves, parapets, balconies, or decks. Failure to comply could result in severe personal injury , death, or substantial property damage. Installation must comply with local requirements and [...]

35 DIRECT VENTING: VERTICAL TERMINA TION Installation must comply with local requirements and with the National Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations. VENT/AIR TERMINA TION LOCA TIONS: Follow these guidelines for locating the vent/air terminations: 1. Make sure the total length of piping for vent[...]

36 ALL VENT PIPE MA TERIALS AND FITTINGS MUST COMPL Y WITH THE FOLLOWING: ITEM MA TERIAL ST ANDARDS FOR INST ALLA TION IN: UNITED ST A TES CANADA V ent pipe and ttings PVC schedule 40 ANSI/ASTM D1785 CPVC and PVC venting must be ULC-S636 Certied. CPVC schedule 40/80 ANSI/ASTM F441 Pipe cement/primer PVC ANSI/ASTM D2564 ULC-S636 Certied. CP[...]

37 CONDENSA TE NEUTRALIZER The condensate drains from the boiler have pH levels between 4.3 and 5.0. The pH measurement of a uid is an indicator of the acidity or alkalinity . Neutral uids have pH of 7.0. Acid uids have pH below 7. Some local codes may require the use of a condensate neutralizer to raise the pH level of the condensate leav[...]

38 6. Use pipe sealing compound compatible with propane gases. Apply sparingly only to male threads of the pipe joints so that pipe dope does not block gas ow . Failure to apply pipe sealing compound as detailed in this manual can result in severe personal injury , death, or substantial property damage. 7. Make sure the maximum inlet gas pressur[...]

39 PIPE SIZES FOR PROP ANE GAS Make sure to contact the gas supplier for pipe sizes, tanks, and 100% lockup gas pressure regulator . PURGING GAS LINE Gas line purging is required with new piping or systems in which air has entered. Gas purging should be performed per NFP A 54 for US and CAN B149.1 for Canada. CHECK GAS SUPPL Y INLET PRESSURE CSA or[...]

40 BOILER ST ART UP AND OPERA TIONS IMPORT ANT Only an A.O. Smith Certied Start-up agent must perform the initial ring of the boiler . At this time the user should not hesitate to ask the start-up 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.[...]

41 T ABLE 18. W A TER HARDNESS MEDIUM (0-12 GRAINS PER GALLON) XW MODEL NO. ∆T ºF GPM ∆P FEET 1000 25 76 17.5 1300 25 99 22 1700 25 129 23 2000 25 152 17.5 2600 25 198 22 3400 25 258 23 ∆T ºF = T emperature rise ºF at the specied GPM. GPM = Flow rate in gallons per minute. ∆P = Pressure loss through the heat exchanger in feet of head.[...]

42 LIGHTING AND OPERA TING INSTRUCTIONS[...]

43 Click on Operation button, and under the Modulation Menu, set the required Firing rate (High/Low) by setting the RPM. On the Firing Rate page, set the Firing rate RPM by selecting the Manual in Run check box. ADJUSTMENT There must be sufcient load to operate the boiler at high re to perform the following adjustments. Start the boiler and o[...]

44 T ABLE 19. HIGH FIRE RA TE T ABLE 20. LOW FIRE RA TE HIGH FIRING RA TE SETTING Set the boiler to the high ring rate by setting the High Firing Rate RPM as described below . Check combustion readings using a combustion analyzer . If combustion readings are not in accordance with the chart below adjust the gas valve as follows: remove the at[...]

45 3. Three Pump Outputs with 5 selectable operation modes. 4. 24V AC: • Output control of gas valve (Pilot and Main) and External Ignition T ransformer. • Digital inputs for room limit control, high limit control, Gas pressure switch, low water cutoff. 5. External spark transformer . 6. Flame Sensor . 7. T est jacks for ame signal measureme[...]

46 CSD-1 Acceptable. Meets CSD-1 section CF-300 requirements as a Primary Safety Control. Meets CSD-1 section CW-400 requirements as a T emperature Operation control. Meets CSD-1 section CW-400 requirements as a T emperature High Limit Control when congured for use with 10 kohm NTC sensors. Federal Communications Commission, Part 15, Class B. Em[...]

47 GENERAL OPERA TIONAL SEQUENCE INITIA TE The R7910 enters the Initiate sequence on Initial Power up or: • V oltage uctuations vary less than 20V AC or greater than 30V AC. • Frequency uctuations vary +/-5% (57 to 63 Hz). • If Demand, LCI, or Stat interrupt (open) during the Prepurge Period. • After the reset button is pressed or fau[...]

48 LEAD LAG (LL) MASTER GENERAL OPERA TION The XP Boiler is a multiple burner application and it works on the basis of the Lead Lag Operation. The XB Boiler is factory congured for Hydronic/Central Heating application, whereas the XW Boiler is factory congured for Domestic Hot W ater application. The LL master coordinates the ring of its s[...]

49 For example: — If its add-stage action has been triggered, it will remain in this condition until either a stage has been added, Or — The criteria for its being in an add-stage condition is no longer met; only then will it take another look around to see what state it should go to next. DEFINITIONS Modulating stage: The modulating stage is t[...]

50 10. Drill 1/4 in. holes through the panel at the marked locations and secure the power supply with the two #6-32 screws and nuts provided. 1 1. Remove the 9-pin connector plug from the back of the OI Display . 12. Wire the connector to the power supply and the RS-485 cables. 13. Ensure the 9-pin connector plug is aligned with the header pins whe[...]

51 On System applications, each Burner Control System is represented on the Home page by an icon and name. Pressing the icon allows the user to zoom in on that boiler and see its specic details. These details are provided on a new page, which can include additional buttons that display additional detail and operation information, which itself le[...]

52 FIGURE 53. S7999B DISPLA Y P AGE FLOW[...]

53 FIGURE 54. SUMMARY ST A TUS P AGE CONFIGURE BUTTON Pressing the Congure button (bottom left) on the Status page opens the Conguration page. The S7999B Conguration page does not have a “Display Setup” button. The conguration page allows the user to view and set parameters that dene how the connected R7910A functions in the hydr[...]

54 KEYBOARD Some pages request user entry of characters. When this type of input is required, a keyboard page appears, as shown in Figure 58. The text box at the top of the screen displays the current (or default) setting of the user input. The user can add to this text, clear it, or change it. The Shift key on the left side of the screen shifts be[...]

55 Note: When the installer proceeds with the safety parameter conguration, the control unlocks the safety parameters in this group and marks them unusable. Failure to complete the entire safety conguration procedure leaves the control in an un- runnable state (lockout 2). All safety conguration parameters in the group should have the same[...]

56 F AUL T/ALARM HANDLING Each Burner Control reports to the OI display when a safety lockout or an Alert occurs. Safety lockouts are indicated on each conguration page as an alarm bell symbol. At the status page (for S7999B), the History button turns red. If the S7999B is displaying the system status icons, the control in alarm will turn red. T[...]

57 Note: The system time can be set in the OI display to ensure that correct timestamps are given to the controls’ lockouts and alerts. Power interruptions will require the time to be reset as the display DOES NOT have a time backup means. The Clear Lockout button allows the user to acknowledge and clear (reset) the lockout when in lockout state,[...]

58 OPERA TION BUTTON The operation button displays the Burner Control running operation, including setpoint and ring rate values. From this page the user can change setpoints, manually control the boiler ’s ring rate, manually turn pumps on, view annunciation information, and switch between hydronic heating loops (Central Heat and Domestic [...]

59 SYSTEM CONFIGURA TION (S7999B OI DISPLA Y ONL Y) The OI Display has some functions related to general conguration for the control in the end user installation. Pressing the Display Refresh button invokes a search procedure (see Figure 74). A new R7910A Hydronic Control or R791 1 Steam Control is identied by “Unknown” status next to its[...]

60 CONFIGURA TION The Burner Control can be congured from the OI Display . The control conguration is grouped into the functional groups as shown in T able 23. HYDRONIC CONTROL System Identication and Access CH - Central Heat Outdoor Reset DHW - Domestic Hot W ater DHW Storage DHW Plate W arm Weather Shutdown Demand Priority Modulation Con[...]

61 T o support the recommended T roubleshooting, the R7910 has an Alert File. Review the Alert history for possible trends that may have been occurring prior to the actual Lockout. Note Column: H= Hold message; L=Lockout message; H or L= either Hold or Lockout depending on Parameter Conguration. CODE DESCRIPTION RECOMMENDED TROUBLESHOOTING OF LO[...]

62 CODE DESCRIPTION RECOMMENDED TROUBLESHOOTING OF LOCKOUT CODES NOTE 30 Internal fault: Flame bias shorted to adjacent pin Internal Fault. 1. Reset Module. 2. If fault repeats, replace module. H 31 Internal fault: SLO electronics unknown error H 32 - 46 Internal fault: Safety Key 0 through 14 L System Errors 47 Flame Rod to ground leakage H 48 Sta[...]

63 CODE DESCRIPTION RECOMMENDED TROUBLESHOOTING OF LOCKOUT CODES NOTE 67 ILK OFF 1. Check wiring and correct any possible shorts. 2. Check Interlock (ILK) switches to assure proper function. 3. V erify voltage through the interlock string to the interlock input with a voltmeter . 4. If steps 1-3 are correct and the fault persists, replace the modul[...]

64 CODE DESCRIPTION RECOMMENDED TROUBLESHOOTING OF LOCKOUT CODES NOTE 94 Header sensor fault 1. Check wiring and correct any possible errors. 2. Replace the header sensor . 3. If previous steps are correct and fault persists, replace the module. H 95 Stack sensor fault 1. Check wiring and correct any possible errors. 2. Replace the stack sensor . 3[...]

65 CODE DESCRIPTION RECOMMENDED TROUBLESHOOTING OF LOCKOUT CODES NOTE 124 High re switch OFF 1. Check wiring and correct any potential wiring errors. 2. Check High Fire Switch to assure proper function (not welded or jumpered). 3. Manually drive the motor to the High Fire position and adjust the HF switch while in this position and verify voltag[...]

66 CODE DESCRIPTION RECOMMENDED TROUBLESHOOTING OF LOCKOUT CODES NOTE 150 Flame not detected OEM Specic 1. Sequence returns to standby and restarts sequence at the beginning of Purge after the HF switch opens. If ame detected during Safe Start check up to Flame Establishing period. H 151 High re switch ON OEM Specic 1. Check wiring and [...]

67 CODE DESCRIPTION RECOMMENDED TROUBLESHOOTING OF LOCKOUT CODES NOTE 164 Block intake ON OEM Specic 1. Check wiring and correct any errors. 2. Inspect the Block Intake Switch to make sure it is working correctly . 3. Reset and sequence the module. 4. During Standby and Purge, measure the voltage across the switch. Supply voltage should be prese[...]

68 CODE DESCRIPTION RECOMMENDED TROUBLESHOOTING OF LOCKOUT CODES NOTE 212 Invalid Preignition time setting 1. Return to Conguration mode and recheck selected parameters, reverify and reset module. 2. If fault repeats, verify electrical grounding. 3. If fault repeats, replace module. L 213 Invalid Prepurge rate setting L 214 Invalid Prepurge time[...]

69 CODE DESCRIPTION 37 Program Module application parameter revision differs from application processor 38 Program Module safety parameter revision differs from safety processor 39 PCB incompatible with product contained in Program Module 40 Parameter PCB in Program Module is too large for product 41 Range PCB in Program Module was too large for pr[...]

70 CODE DESCRIPTION 11 4 MIX modulation range (max minus min) was too small (< 4% or 40 RPM) Modulation Operation Faults 11 5 Fan was limited to its minimum duty cycle 11 6 Manual rate was > CH max modulation rate 11 7 Manual rate was > DHW max modulation rate 11 8 Manual rate was < min modulation rate 11 9 Manual rate in Standby was &g[...]

71 CODE DESCRIPTION 191 Lead Lag base load common setting was invalid 192 Lead Lag DHW demand switch setting was 193 Lead Lag Mix demand switch setting was invalid 194 Lead Lag modulation sensor setting was invalid 195 Lead Lag backup modulation sensor setting was invalid 196 Lead Lag slave mode setting was invalid 197 Lead Lag rate allocation sett[...]

72 CODE DESCRIPTION 274 Abnormal Recycle: Demand off during Pilot Flame Establishing Period 275 Abnormal Recycle: LCI off during Drive to Purge Rate 276 Abnormal Recycle: LCI off during Measured Purge T ime 277 Abnormal Recycle: LCI off during Drive to Lightof f Rate 278 Abnormal Recycle: LCI off during Pre-Ignition test 279 Abnormal Recycle: LCI o[...]

73 CODE DESCRIPTION 341 Abnormal Recycle: Hardware SLO electronics 342 Abnormal Recycle: Hardware processor clock 343 Abnormal Recycle: Hardware AC phase 344 Abnormal Recycle: Hardware A2D mismatch 345 Abnormal Recycle: Hardware VSNSR A2D 346 Abnormal Recycle: Hardware 28V A2D 347 Abnormal Recycle: Hardware HFS IAS shorted 348 Abnormal Recycle: Har[...]

74 CODE DESCRIPTION 482 Internal error: Safety key bit 4 was incorrect 483 Internal error: Safety key bit 5 was incorrect 484 Internal error: Safety key bit 6 was incorrect 485 Internal error: Safety key bit 7 was incorrect 486 Internal error: Safety key bit 8 was incorrect 487 Internal error: Safety key bit 9 was incorrect 488 Internal error: Safe[...]

75 CODE DESCRIPTION 571 Heat exchanger high limit response was invalid 572 Heat exchanger high limit was exceeded 573 Heat exchanger high limit wasn't allowed due to stack limit setting 574 Heat exchanger high limit wasn't allowed due to stack connector setting 575 Heat exchanger high limit delay was not congured for recycle response P[...]

76 INSPECT BOILER AREA 1. V erify that boiler area is free of any combustible materials, gasoline and other ammable vapors and liquids. 2. V erify that air intake area is free of any of the contaminants. If any of these are present in the boiler intake air vicinity , they must be removed. If they cannot be removed, reinstall the air and vent lin[...]

77 5. Loosen the seven bolts on the blower adapter at the base and move the burner ground wire (Green) aside. 6. Lift the blower adapter and remove the manifold assembly up from the 6 studs located on the cover plate and remove the burner gasket. 7. Remove any loose foreign material such as dust or lint with a vacuum. Check all ports for blockage. [...]

78 1. Turn of f the electrical power , and manual gas shut-off.  • Allow boiler parts to cool before disassembly . 2. Remove the vent pipe. • 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. [...]

79 HANDLING CERAMIC FIBER MA TERIALS Removal of combustion chamber lining: The combustion chamber insulation in this boiler contains ceramic ber material. Ceramic bers can be converted to cristobalite in very high temperature applications. The International Agency for Research on Cancer (IARC) has concluded, “Crystalline silica in the form [...]

80 PIPING DIAGRAMS FIGURE 78. PRIMAR Y/SECONDAR Y PIPING SYSTEM NOTES: 1. Preferred piping diagram. 2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system. 3. Service valves are shown for servicing unit. However , local codes shall govern their usage. 4. The boiler is shown with the opti[...]

81 AOS STORAGE TANK HOT WATER TO FIXTURES FINISHED FLOOR EXPANSION TANK ALTERNATE CONNECTION COLD WATER SUPPLY SYSTEM RETURN NOTES: 1. Preferred piping diagram. 2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system. 3. Service valves are shown for servicing unit. However, local codes sh[...]

82 LIMITED W ARRANTY A. O. Smith Corporation, the warrantor , extends the following LIMITED W ARRANTY to the owner of this boiler: 1. If within TEN years after initial installation of the boiler , a heat exchanger or gas burner should prove upon examination by the warrantor to be defective in material or workmanship, the warrantor , at his option w[...]

83 25589 Highway 1, McBee, SC 29101 T echnical Support: 800-527-1953 • Parts: 800-433-2545 • Fax: 800-644-9306 www .hotwater .com[...]